Combat ® UHD-Series Tubular Duct Furnace (Standard Range) Installation, Operation & Service Manual Models UHD[X][S][R] 150, 175, 200, 225 250, 300, 350, 400 WARNING Improper installation, adjustment, alteration, service or maintenance can result in death, injury or property damage. Read the Installation, Operation and Service Manual thoroughly before installing or servicing this equipment. Installer Please take the time to read and understand these instructions prior to any installation.
TABLE OF CONTENTS SECTION 1: Heater Safety...................................................... 1 1.1 Manpower Requirements ............................................. 1 SECTION 2: Installer Responsibility ..................................... 2 2.1 Wall Tag ....................................................................... 2 2.2 Corrosive Chemicals.................................................... 2 2.3 National Standards and Applicable Codes ..................
TABLE OF FIGURES Figure 1: Clearances to Combustibles ...................................... 3 Figure 2: Air Flow Direction....................................................... 7 Figure 3: Suspension Methods ................................................. 8 Figure 4: Vent and Roof Detail ................................................ 11 Figure 5: Standard Vented Heater - Vertical and Horizontal Vent Termination......................................................
SECTION 1: HEATER SAFETY SECTION 1: HEATER SAFETY Your Safety is Important to Us! This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnings in these sections. Installation, service and quarterly inspection of heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 2: INSTALLER RESPONSIBILITY The installer is responsible for the following: • To install the heater, as well as the gas and electrical supplies, in accordance with applicable specifications and codes. Roberts-Gordon recommends the installer contact a Local Building Inspector or Fire Marshal for guidance.
SECTION 3: CRITICAL CONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS 3.1 Basic Information UHD[X][S][R] heaters have automatic ignition burners for ON/OFF operation only. 3.2 Manufactured Units Gas-fired, power-vented duct furnace with tubular heat exchanger. Units shall have a minimum of 82% thermal efficiency. The standard unit shall consist of a non-separated combustion design with an aluminized heat exchanger.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 3.8 Electrical Supply 3.6 Ventilation WARNING WARNING Carbon Monoxide Hazard Heaters may be installed vented or unvented. Vented heaters must be vented outdoors. Electrical Shock Hazard Unvented heaters must be installed in buildings with ventilation rates as per section 6.4. Failure to follow these instructions can result in death or injury.
SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.1 Gas Codes The type of gas appearing on the name plate must be the type of gas used. Installation must comply with national and local codes and requirements of the local gas company. United States: Refer to NFPA 54/ANSI Z223.1 latest revision, National Fuel Gas Code. Canada: Refer to CSA B149.1 Natural Gas and Propane Installation Code. 4.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 4.6 High Altitude These heaters are CSA-approved (without modifications) for installations up to 2000' (610 m) in US and 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 derating. For installations from 2000' (610 m) to 4500' (1370m) in Canada, high altitude conversion kits are available.
SECTION 5: DUCT HEATER INSTALLATION SECTION 5: DUCT HEATER INSTALLATION 5.1 General To connect the inlet and outlet ducts to the heater, Duct-Mate or similar flanges may be slid over the duct connector flanges supplied on the unit and secured with screws. The connection to the duct then can be made using the Duct-Mate clips. The ducts must have removable access panels upstream and downstream of the heater.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 5.1.3 Air Flow And Temperature Rise Ranges Model Rate (Btu/h) 150,000 175,000 200,000 225,000 250,000 300,000 350,000 385,000 UHD[X][S][R] 150 UHD[X][S][R] 175 UHD[X][S][R] 200 UHD[X][S][R] 225 UHD[X][S][R] 250 UHD[X][S][R] 300 UHD[X][S][R] 350 UHD[X][S][R] 400 Air Flow Minimum (CFM) Maximum (CFM) 1,360 5,800 1,400 6,850 2,050 7,750 2,100 8,300 2,350 8,850 2,700 10,200 3,120 13,600 3,420 14,200 5.
SECTION 6: VENTING SECTION 6: VENTING 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 6.4. Failure to follow these instructions can result in death or injury. 6.1 Changing Vent and Air Intake Orientation The heater is sold with rear horizontal vent and air intake connections. (Only separated combustion models have air intake connection.) 6.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL Vents and air intakes must be adequately supported so that the heater does not bear the weight of the pipes. For vent termination See Page 11, Figure 4 through Page 14, Figure 9. States); 3 cfm per 1000 Btu/h firing rate (Canada). 6.3.1 Standard Vented Heaters (Models UHD[X][R] 150 - 400) The vent must be fitted with a low resistance terminal. See Page 11, Figure 4 through Page 12, Figure 5.
SECTION 6: VENTING The entire vent should be insulated with foil faced fiberglass insulation (1/2" thick, 1-1/2# density minimum). 6.7.1 Maximum Vent Lengths Model UHD[X][S][R] 150 - 400 40 ft (12.2 m) 35 ft (10.7 m) 30 ft (9.1 m) 25 ft (7.6 m) 20 ft (6.1 m) Number of Elbows 1 2 3 4 5 6.8 Vent Material Vent material may be single wall 26 ga. (minimum) galvanized steel or equal thickness stainless steel. Completely seal all joints, refer to Page 9, Section 6.3.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL Figure 5: Standard Vented Heater - Vertical and Horizontal Vent Termination Model Vent Diameter UHD[X][R] 150 - 400 4" (10 cm) Part Number 90502102 Figure 6: Standard Vented Heater - Common Vertical Vent Termination 12
SECTION 6: VENTING Figure 7: Separated Combustion Heater - Vertical and Horizontal Vent Termination 12" (31 cm) Minimum from air inlet to vent termination (may be horizontal or vertical clearance). NOTE: Vent supports not shown. Duct supports not shown. Duct and 12" (31 cm) vent supports not Minimum from provided by the wall to vent manufacturer. termination. Vent Air Intake* Vertical Option 12" (31 cm) Minimum from air inlet to vent termination (may be horizontal or vertical clearance).
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL Figure 9: Concentric Vertical and Horizontal Vent Termination - Separated Combustion Heater Description Concentric Vent Kit (150 - 250) Concentric Vent Box Top & Side Assembly Concentric Vent Box Bottom Assembly Screw #6 x 3/8 Self Drilling 4" (10 cm) Vent Terminal with Baffle Plate 6" (15 cm) Combustion Air Terminal Part Number UHVK1 90504113 90504112 91119100 90502102R 90502103 Qty.
SECTION 7: AIR SUPPLY SECTION 7: AIR SUPPLY 7.1 Separated Combustion Installation When installed as a separated combustion heater (UHD[X]S[R]), the air for combustion is drawn in from outside the building. 7.2 Unvented Installation It is important to ensure that there is adequate fresh air supply at all times for both combustion and heating requirements in accordance with local and national codes.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 8: GAS PIPING Fire Hazard Connect gas supply according to Figure 10. Do not use gas supply pipe and electrical connections to support heater’s weight. Gas can leak if not installed properly. Failure to follow these instructions can result in death, injury or property damage. A gas meter is connected to the service pipe by the gas supply company.
SECTION 9: WIRING SECTION 9: WIRING WARNING Electrical Shock Hazard Disconnect electrical and gas supply before servicing. This appliance must be connected to a properly grounded electrical source. Failure to follow these instructions can result in death or electrical shock. All heater models require constant 120 V/1Ø/60 Hz power supply. Check heater rating plate for electrical rating for proper circuit sizing.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 9.
SECTION 9: WIRING 9.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 9.5 Electrical Connection to the Heater Flexible Conduit BX Connector Burner Connect wires together with suitable approved wire connectors. L1 L2 Ground Green to Ground White to L2 Black to L1 Black White Green Junction Box IMPORTANT: Junction box is not provided with heater. Conduit can also be attached directly to heater with wire junction made within the heater cabinet.
SECTION 10: OPERATION AND MAINTENANCE SECTION 10: OPERATION AND MAINTENANCE 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 electrical supplies before performing service or maintenance. 10.2 Begin Start-Up 10.2.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL Figure 11: Automatic Burner Control Sequence Burner Sequence for Ignition Control START RUN SHUT DOWN Thermostat 24 V Flue Blower 30 Seconds Purge* Pressure Switch P C 30 Seconds Post Purge NO NC ts = 10 Seconds Ignition Spark Start Gas Valve Flame Signal *Purge time begins at pressure switch change over. Required Incoming Signals Signals Output By Control If at any stage the flame fails, the control will retry for ignition.
SECTION 10: OPERATION AND MAINTENANCE 10.2.2 Start-Up the Gas Valve (All Gases) 10.2.2.1 Check Burner Gas Pressure 1. Remove the plug in the outlet (burner) pressure test point and connect a pressure tap and a manometer. 2. With the burner firing, measure the pressure on the manometer.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 11: USER INSTRUCTIONS 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 electrical supplies before performing service or maintenance. Failure to follow these instructions can result in death, injury or property damage. 11.
SECTION 12: SERVICING SECTION 12: SERVICING 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 electrical supplies before performing service or maintenance. Failure to follow these instructions can result in death, injury or property damage. 12.1 Servicing Instructions After start-up, the heater will require maintenance to be carried out annually.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 12.7 Maintenance Checklist 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 electrical supplies before performing service or maintenance. Failure to follow these instructions can result in death, injury or property damage.
SECTION 12: SERVICING Gas Line and Shut-off Valves Check for gas leaks. Burner Observation Window Make sure it is clean and free of cracks or holes. See Page 16, Section 8. Clean and replace as required. Flue Blower Scroll, Wheel Compressed air or a vacuum cleaner may be used to clean dust and dirt. and Motor Inshot Burners and Clear obstructions (even spider webs will cause problems). Orifices Carefully remove any dust and debris from the burner.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 13: TROUBLESHOOTING 13.1 General WARNING START Are gas & electrical supplies on? No Turn on supplies. 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 electrical supplies before performing service or maintenance.
SECTION 13: TROUBLESHOOTING 13.2 Troubleshooting For Automatic Ignition Burner Systems START Are gas & electrical supplies on? No Turn on supplies. No Turn on controls. Yes Are external controls (i.e. Thermostat) on? Yes Is ignition control showing a "4 flashes" LED code? Yes Wait 10 - 15 minutes for limit switch to cool. Does fan stop running? Yes Fan and limit switch are operating normally. No Replace temperature limit switch.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 13.3 Troubleshooting for Flame Supervision System To measure flame current, connect a 0 - 50 μA DC meter in series with the flame probe. If the meter reads negative values, then reverse the test leads. START Connect a DC ammeter in series with the flame probe. Is the flame present and at least 1 μA DC flame current? No Use General Troubleshooting section to trace the fault.
SECTION 13: TROUBLESHOOTING 13.4 Troubleshooting for Gas Valves START Is gas pressure at inlet of the valve correct for gas type? Note pressure found. No Fault elsewhere. Correct pressure problem. No Valve or ignition control faulty. Replace with one of correct type. No Valve faulty. Replace with one of correct type. No If problems persist, contact Roberts-Gordon LLC at www.rg-inc.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 14: REPLACEMENT PARTS Burner Components All serviceable burner parts are accessed by the door on the side of the heater. Remove the sheetmetal screws. WARNING 14.1 Gas Valve Remove the gas supply pipe at the heater inlet. 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.
SECTION 14: REPLACEMENT PARTS 14.2 Burner Compartment The burner compartment is a sealed compartment. Following any work, re-seal the compartment with the gas pipe rubber seal fully in place and all screws fitted and tight. Burner Compartment Cover Flame Probe Viewing port for flame probe Remove flexible air duct from spigot Ignition Electrode NOTE: Separated combustion model shown.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 14.3 Ignition Electrode and Flame Probe 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.
SECTION 14: REPLACEMENT PARTS 14.4 Heat Exchanger The heat exchanger consists of a four-pass design with 1.75" outer diameter [409 stainless steel] tube. The tube plates are made of [aluminized steel] [409 stainless steel]. The tube supports are made of [galvannealed steel] [409 stainless steel]. 14.5 Flue Blower Remove screws securing outlet flange to the flue adapter. Refit in reverse order. Remove screws securing flue blower mounting plate to vent box. Remove screws securing mounting plate to blower.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 14.6 Pressure Switch Pull off 3 way connector. Spring open plastic clips of mounting cradle. Replace with correct type of pressure switch for model. The pressure switches are color coded for each pressure setting. Carry out a start-up after working on or changing a pressure switch. See Page 21, Section 10.
SECTION 15: SPECIFICATIONS SECTION 15: SPECIFICATIONS 15.1 Dimension Data Heater must be supported at these points from above or below. F TOP VIEW E D Support Centers C 4 x 3/8" Captive Nuts Provided 19.4" (49 cm) C END VIEW M 25.5" (65 cm) C REAR VIEW C M Air Intake (UHD[X][S][R] only) G H B J Thermostat Connection Flue Gas Supply Electrical Supply 6.5" (17 cm) 2.
UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 15.
SECTION 16: THE ROBERTS GORDON® COMBAT® UHD-SERIES WARRANTY SECTION 16: THE ROBERTS GORDON® COMBAT® UHD-SERIES WARRANTY ROBERTS GORDON® WILL PAY FOR: Within 24 months from date of purchase by buyer or 27 months from date of shipment by Roberts-Gordon (whichever comes first), replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect. Roberts-Gordon will require the part in question to be returned to the factory.
® Wa r m Air Heating OWNER WARRANTY REGISTRATION CARD 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.
Attach this information to the wall near the ROBERTS GORDON® heater ® Read the Installation, Operation and Service Manual thoroughly before installation, operation or service. WARNING OPERATING INSTRUCTIONS 1. STOP! Read all safety instructions on this information sheet. 2. Open the manual gas valve in the heater supply line. 3. Turn on electric power to the heater. 4. Set the thermostat to desired setting (above ambient temperature). The automatic starting sequence begins. TO TURN OFF THE HEATER 1.