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Roberts-GordonOxford StreetBilston, West Midlands WV14 7EG UKTelephone: +44(0) 1902 494425Fax: +44(0) 1902 403200Service Telephone: +44(0) 1902 498733Service Fax: +44(0) 1902 401464Export Sales Telephone: +44(0) 1794 521562Export Sales Fax: +44(0) 1794 521387E-mail: [email protected]: [email protected] www.rg-inc.com

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© Copyright 2002 Roberts-Gordon

Quality in Any Language™

Installation, Commissioning,Operation & Service Manual

Model CUH(A, B, C, D)

60 to 240 Manual Ignition

Model CUH(A/A, B/A, C/A, D/A)

60 to 380 Automatic Ignition

X404E Rev A 07/02

Unit Heaters

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Printed in U.K.

TABLE OF CONTENTS...................................................................Product Approval 1SECTION 1: Heater Safety...................................................... 2SECTION 2: Installer Responsibility ..................................... 2

2.1 Low Level User Instructions......................................... 22.2 Corrosive Chemicals.................................................... 22.3 National Standards and Applicable Codes .................. 2

SECTION 3: Critical Considerations ..................................... 33.1 Basic Information ......................................................... 33.2 Location and Suspension ............................................ 33.3 Minimum Required Clearances to Combustibles......... 33.4 Ventilation .................................................................... 33.5 Gas Supply .................................................................. 33.6 Electrical Supply .......................................................... 33.7 Flue.............................................................................. 3

SECTION 4: Specifications .................................................... 64.1 All Models .................................................................... 64.2 Components Identification ........................................... 74.3 General Technical Data Table (all models) .................. 84.4 Technical Data Table - CUHA, CUHB, CUHC and

CUHD Manual Ignition Range ..................................... 94.5 Technical Data Table - CUHA/A, CUHB/A, CUHC/A

and CUHD/A Automatic Ignition Range .................... 104.6 Gas Controls - Automatic Ignition .............................. 114.7 Gas Controls - Manual Ignition .................................. 114.8 Main Fan.................................................................... 114.9 Limit Thermostats ...................................................... 114.10 Thermocouple Interrupter Relay .............................. 114.11 Automatic Ignition - Burner Control Box .................. 11

SECTION 5: Heater Installation............................................ 135.1 General ......................................................................135.2 Handling .................................................................... 135.3 Shelf Mounting and Suspension ................................ 13

SECTION 6: Flue Installation ............................................... 146.1 Flue Installation ......................................................... 146.2 Models 340 and 380 only .......................................... 16

SECTION 7: Air Supply......................................................... 177.1 Air Supply .................................................................. 177.2 Building Ventilation .................................................... 17

SECTION 8: Optional Heater Configurations ..................... 188.1 Distribution Ductwork for CUHB, CUHC and CUHD

Heaters ......................................................................18SECTION 9: Gas Piping........................................................ 20SECTION 10: Wiring and Electrical Information ................ 21

10.1 Electrical Supply ...................................................... 2110.2 Remote Controls...................................................... 2110.3 CUH Individual Controls (all models)....................... 2210.4 CUHD External Motor Alternative Wiring

(all models) .............................................................. 2210.5 CUHA Wiring Diagram............................................. 2310.6 CUHB & CUHC Wiring Diagram (60-160) ............... 2310.7 CUHB & CUHC Wiring Diagram (180-240) ............. 2410.8 CUHD Wiring Diagram (all models) ......................... 2510.9 CUHA/A Wiring Diagram (60-240) Satronic............. 2610.10 CUHA/A Wiring Diagram (280-300) Satronic......... 2710.11 CUHA/A Wiring Diagram (340-380) Satronic......... 2710.12 CUHB/A & CUHC/A Wiring Diagram (60-160)

Satronic ................................................................. 2810.13 CUHB/A & CUHC/A Wiring Diagram (180-300)

Satronic ................................................................. 29

10.14 CUHB/A & CUHC/A Wiring Diagram (340-380) Satronic .................................................................30

10.15 CUHD/A Wiring Diagram (60-300) Satronic...........3110.16 CUHD/A Wiring Diagram (340-380) Satronic.........3110.17 CUHA/A Wiring Diagram (60-240) Honeywell........3210.18 CUHA/A Wiring Diagrams (280-300) Honeywell....3310.19 CUHA/A Wiring Diagram (340-380) Honeywell......3310.20 CUHB/A & CUHC/A Wiring Diagram (60-160)

Honeywell ..............................................................3410.21 CUHB/A & CUHC/A Wiring Diagram (180-300)

Honeywell ..............................................................3510.22 CUHB/A & CUHC/A Wiring Diagram (340-380)

Honeywell .............................................................3610.23 CUHD/A Wiring Diagram (60-300) Honeywell .......3710.24 CUHD/A Wiring Diagram (340-380) Honeywell .....37

SECTION 11: Commissioning The Heater ..........................3811.1 Pre Commission Checks..........................................3811.2 Gas Supply ..............................................................3811.3 Mechanical Checks ..................................................3811.4 Automatic Ignition Unit Heaters ...............................3911.5 Manual Ignition Unit Heaters....................................4211.6 Commissioning Tests - (all models)

Spillage Test.............................................................4311.7 Combustion Testing - (all models)............................4311.8 Pilot Drop-Out Test - Manual Ignition Models ..........4311.9 Turning Off the Heater - (all models)........................4311.10 External Controls ...................................................4311.11 Complete the Installation .......................................4311.12 Instruction to the User............................................43

SECTION 12: User Instructions ...........................................4412.1 User Instructions ......................................................4412.2 Heater Operation .....................................................4412.3 Common User Controls (all models)........................4412.4 Automatic Ignition User Controls .............................4512.5 Automatic Ignition Lighting Instructions ...................4512.6 Manual Ignition User Controls..................................4512.7 Manual Ignition Lighting Instructions........................4512.8 Simple Fault Finding (all models).............................4612.9 Service Requirements .............................................47

SECTION 13: Servicing.........................................................4813.1 Servicing Instructions...............................................4813.2 Fan/Motor Assembly Maintenance

(all models)...............................................................4813.3 Heat Exchanger Maintenance..................................4813.4 Gas Control Valve Maintenance (all models) ...........4913.5 Manual Ignition.........................................................49

SECTION 14: Conversion Between Gases..........................5014.1 General ....................................................................5014.2 Burner Conversion ...................................................5014.3 Gas Valves - Automatic Ignition ...............................5014.4 Conversion of Manual Ignition Valves ......................52

SECTION 15: Troubleshooting .............................................5315.1 General for Automatic Ignition..................................5315.2 Troubleshooting For Automatic Ignition Burner

Systems...................................................................5515.3 Flame Supervision System ......................................5715.4 Troubleshooting for Solenoid Valves ........................5815.5 Troubleshooting for Main Fan...................................5815.6 Troubleshooting for Fan Contactor ...........................59

SECTION 16: Removal and Replacement Parts ................. 6016.1 Burner Tray .............................................................. 6016.2 Main Burner Bars / Injectors.................................... 6016.3 Pilot Burner Assembly (where fitted). ...................... 6216.4 Gas Control Valves.................................................. 6316.5 CUHA Axial Fan/Guard/Motor Assembly................. 6316.6 CUHB & CUHC Centrifugal Fan/Guard/Motor

Assembly................................................................. 6416.7 Combination Fan/Limit Thermostat ......................... 6416.8 Second Limit Thermostat ........................................ 6416.9 Major Components Descriptions ............................. 66

TABLE OF FIGURESFigure 1: Clearances to Combustibles...................................... 4Figure 2: Flue Termination ........................................................ 5Figure 3: Offset Flues with 135° bends..................................... 5Figure 4: Ducting ...................................................................... 5Figure 5: Combination Fan/Limit Thermostat.......................... 12Figure 6: Honeywell Control ................................................... 12Figure 7: Suspension Methods ............................................... 13Figure 8: Guy Wire.................................................................. 14Figure 9: Socket Direction....................................................... 14Figure 10: Flue and Roof Detail .............................................. 15Figure 11: Flue and Heater Spigot Joint Detail ....................... 15Figure 12: Heaters installed in isolated equipment rooms. ..... 19Figure 13: CUH C or D Heaters with Inlet/Outlet Duct

Spigots and Flange................................................ 19Figure 14: Gas Connection with Stainless Steel Flex

Connector .............................................................. 20Figure 15: Setting Louvers...................................................... 38Figure 16: S.I.T. Tandem 0.830.033 Gas Valve

(Natural gas) 0.830.020 Valve (L.P.G) ................... 40Figure 17: S.I.T. Nova 0.822.177 Automatic Ignition

Gas Valve .............................................................. 40Figure 18: S.I.T. Nova 0.820.054 Manual Ignition

Gas Valve .............................................................. 41Figure 19: Main Gas Valves for Models 340 and 380 ............. 41Figure 20: Heater Operating Sequence.................................. 44Figure 21: Fan/Limit Thermostat ............................................. 44Figure 22: S.I.T. Nova Valve for Manual Ignition,

Operation ............................................................... 46Figure 23: Pilot Burner Options .............................................. 50Figure 24: Conversion of Nova Family Valve .......................... 51Figure 25: Conversion of Honeywell Gas Valve for L.P.G. ...... 51Figure 26: Automatic Burner Control Box Sequence ..............56

1

Product Approval

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COMBAT® CUH UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL

2

SECTION 1: HEATER SAFETYYour 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 Annual Inspection of heater must be done by a registered installer/contractor qualified in the installation and service of gas-fired heating equipment.

Read this manual carefully before installation, operation, or service of this equipment.

This heater is designed for heating non-residential indoor spaces. Do not install in residential spaces. 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.

SECTION 2: INSTALLER RESPONSIBILITY• To install the heater, as well as the gas and elec-

trical supplies, in accordance with applicable specifications and codes. Roberts-Gordon recommends the installer contact a local building inspector, Fire Officer or insurance company for guidance.

• To use the information given in the manual together with the cited codes and regulations to perform the installation.

• To install the heater in accordance with the Clearances to Combustibles of this heater.

• To furnish all needed materials not furnished as standard equipment.

• To plan location of supports and flues.

• To provide access to burners for servicing, for burner removal.

• To provide the owner with a copy of this installation, commissioning, operation and service manual.

• To never use heater as support for ladder or other access equipment and never hang orsuspend anything from heater.

• To ensure that there is sufficient ventilation in the area to comply with the requirements of all relevant safety and local regulations.

2.1 Low Level User InstructionsIn all situations, clearances to combustibles must be maintained. See Page 4, Figure 1.

2.2 Corrosive Chemicals

Roberts-Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation; this is entirely the responsibility of the installer. It is essential that the contractor, the sub-contractor, or the owner identifies the presence of combustible materials, corrosive chemicals or halogenated hydrocarbons* anywhere in the premises.

* Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These com-pounds are frequently used in refrigerants, cleaning agents, solvents, etc. If these compounds enter the air supply of the burner, the lifespan of the heater compo-nents will be greatly reduced. Warranty will be invalid if the heater is exposed to halogenated hydrocarbons.

2.3 National Standards and Applicable CodesAll Appliances must be installed in accordance with the latest revision of applicable standards and national codes. This refers also to the electric, gas and venting installation. Note: Additional standards for installations in Public Garages, Aircraft Hangars, etc. may be applicable.

• Gas Safety (Installations and Use) Regulations 1994.

• BS 6230 Specification for the Installation of Gas Fired Forced Convection Air Heaters for Commercial and Industrial Space Heating of Rated input Exceeding 60kW.

• BS 6891 Installation of Low Pressure Pipes up to 28mm (R1) or Institute of Gas Engineers Doc-uments IGE/UP/1 and IGE/UP/2 as appropriate.

• BS 5588 Part 11 Fire Precautions In the Design and Construction of Buildings.

• Building Regulations; The I.E.E Regulations; The Health and Safety at Work etc. Acts; Any Requirements of the Local Authority, Fire Officer and Insurance Company.

• BS 5440 Parts 1 Installation of Flues and Ventilation of Gas appliances of Rated Input Not Exceeding 60kW.

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SECTION 3: CRITICAL CONSIDERATIONS

3

SECTION 3: CRITICAL CONSIDERATIONS3.1 Basic InformationThe following types of heaters in the CUH range are covered by these instructions and are for ON/OFF operation only. High/Low or modulating versions are covered in a supplement.

Fan Type Manual Ignition Automatic Ignition

Axial CUHA 60 to 240 CUHA/A 60 to 380

Centrifugal CUHB 60 to 240 CUHB/A 60 to 380

Ducted Inlet CUHC 60 to 240 CUHC/A 60 to 380

No Fan CUHD 60 to 240 CUHD/A 60 to 380

COMBAT® CUH ranges of unit air heaters are type B11 appliances for vertical flue.Models in the 80 to 380 range are for use with natural gas or L.P.G. as stated on the heater data plate. Models 60 are for use with natural gas only. All models are intended for indoor installation only.

3.2 Location and SuspensionAll models must be installed in a level position and may be suspended from above (See Page 13, Figure 7) or from wall brackets of sufficient strength to support the heater as listed in the General Technical Data Table on Page 8, Section 4.3. Drop rods must be a minimum of 10 mm diameter mild steel. Four hanging brackets are located on top of the heater. All heaters may be mounted on a shelf of non combustible material. It is important that the lower front and rear panels remain accessible for burner routine maintenance and repairs. The burner may only be removed from the front lower panel. The rear lower panel must be removed to accomplish this.

3.3 Minimum Required Clearances to CombustiblesClearances around the heater and flue must be as indicated on Page 4, Figure 1 through Page 5, Figure 3 to ensure access for servicing, correct operation and to maintain the clearance to combustibles.

3.4 VentilationIt is important to ensure that there is adequate air circulation around the heater to supply air for combustion, ventilation and distribution in accordance with local codes.

3.5 Gas Supply It is important that the gas supply pipe and the electrical connections do not support any of the heater’s weight.

3.6 Electrical SupplyA permanent 230v 50Hz electrical supply is required at the main electrical terminals. The heater also requires suitable energy controls in accordance with Section 10.

3.7 Flue Choose heater siting to allow for the proper location of the flue. Each heater must be fitted with an individual and correctly sized stainless steel flue (See Page 6, Section 4). No other appliance may be connected to the flue. It is important that flues are designed to prevent down draughts. It is essential that the spillage test on Page 43, Section 11.6 is carried out.


4

Figure 1: Clearances to Combustibles

Installation Clearances to Combustibles for all models:

Model Aback of fan

(m)

Bsides(m)

Crecommended

mounting height (m)

Dburner removal

(m)

Ecombustibles

(m)

Fabove

(m)

CUHA 0.6 0.8 2.75 - 3.0 1.1 3.0 0.6

CUHB 0.6 0.8 2.75 - 3.75 1.1 3.0 0.6

CUHC See Figure 4 0.8 2.75 - 3.75 1.1 3.0 0.6

CUHD See Figure 4 0.8 N/A 1.1 3.0 0.6

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SECTION 3: CRITICAL CONSIDERATIONS

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Figure 2: Flue Termination Figure 3: Offset Flues with 135° bends

Figure 4: Ducting

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SECTION 4: SPECIFICATIONS4.1 All Models

Dimension Data - All Models

* Duct spigots width for models CUHC and CUHD. Duct spigots ’Height’ shown on above drawings.Duct spigots are complete with 30 mm mez. flange.

Model Ref.

60 80 100 120 140 160 180 200 240 280 300 340 380

A Widthmm(in)

519(20½)

519(20½)

589(23)

589(23)

729(28½)

729(28½)

869(34)

869(34)

1009(39¾)

1219(48)

1219(48)

1359(53½)

1499(59)

B Sup-port Spacing

mm(in)

479(18)

479(18)

549(21¾)

549(21¾)

689(27¼)

689(27¼)

829(32¾)

829(32¾)

969(38¼)

1179(46½)

1179(46½)

1319(52)

1459(59)

C Flue Diameter

mm(in)

178(7)

178(7)

178(7)

178(7)

178(7)

178(7)

229(9)

229(9)

254(10)

254(10)

254(10)

305(12)

305(12)

D Inlet & Outlet Spigot Width

mm(in)

438(17¼)

438(17¼)

508(20)

508(20)

648(25¼)

648(25¼)

788(31)

788(31)

928(36½)

1137(44¾)

1137(44¾)

1277(50¼)

1417(55¾)

Weight (CUHA) kg 91 91 110 110 130 130 150 150 190 200 200 210 210Weight (CUHB) kg 111 111 130 130 150 150 170 180 220 270 270 276 276Weight (CUHC) kg 128 128 148 148 169 169 191 201 243 295 295 303 304Weight (CUHD) kg 82 82 92 99 104 114 124 134 154 180 180 190 190

Front Views

Side Views

CUHA Models 60 - 380 CUHB Models 60 - 380

CUHC Models 60 - 380 CUHD Models 60 - 380

CUHA/B/C Models 60 - 300 CUHA/B/C Models 340 - 380 CUHD (and other models fitted withair outlet spigots) Models 60 - 380

SECTION 4: SPECIFICATIONS

7

4.2 Components Identification

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4.3 General Technical Data Table (all models)

MODEL REFERENCE 60 80 100 120 140 160 180 200 240 280 300 340 380

’A’ RANGE

Total Electrical LoadWatts 191 191 191 228 228 444 444 384 384 849 849 849 849

Fan TypeSifan PMG35041-101

Sifan PMG35041-101

Sifan PMG35041-101

Sifan PMG39041-101

Sifan PMG39041-101

Sifan PMG42041-101

Sifan PMG42041-101

Sifan PMG35041-101

Sifan PMG35041-101

Sifan PMG42041-101

Sifan PMG42041-101

Sifan PMG42041-101

Sifan PMG42041-101

Number ofFans Fitted

1 1 1 1 1 1 1 2 2 2 2 2 2

Capacitor µf 2.5 2.5 2.5 3 3 5 5 2 x 2.5 2 x 2.5 2 x 5 2 x 5 2 x 5 2 x 5

Rating - Watts 170 170 170 210 210 180 180 170 170 180 180 180 180

Run Current - Amps 0.7 0.7 0.7 0.86 0.86 1.8 1.8 1.54 1.54 3.56 3.56 3.56 3.56

Start Current - Amps 1.9 1.9 1.9 2.3 2.3 3.4 3.4 4.2 4.2 6.7 6.7 6.7 6.7

Air Flow - m³/hr 2690 2690 3300 3820 4044 4706 4383 4560 6350 9310 9310 9376 9376

Air Flow - ft³/min 1583 1583 1942 2248 2380 2770 2580 2684 3737 5480 5480 5519 5519

'B' & 'C' RANGES

Total Electrical LoadWatts

900 900 1200 1200 1175 1175 1750 2200 2400 2400 2400 3500 3500

Number ofFans Fitted

1 1 1 1 1 1 2 2 2 2 2 3 3

Direct Drive FanTORIN

270-270TORIN

270-270TORIN

270-270TORIN

270-270TORIN

270-270TORIN

270-270TORIN

241-241TORIN

241-241TORIN

270-270TORIN

270-270TORIN

270-270TORIN

270-270TORIN

270-270

Motor Details

Size Watts 1 x 550 1 x 550 1 x 550 1 x 550 1 x 550 1 x 550 2 x 550 2 x 550 2 x 550 2 x 550 2 x 550 3 x 550 3 x 550

Normal Set Speed LOW LOW MEDIUM MEDIUM MEDIUM MEDIUM LOW MEDIUM MEDIUM MEDIUM MEDIUM MEDIUM MEDIUM

Normal Run CurrentAmps 3.9 3.9 5.2 5.2 5.1 5.1 7.5 9.4 10.3 10.3 10.3 15 15

Normal Start CurrentAmps

4.8 4.8 6.4 6.4 6 6 9.3 11.6 12.8 12.772 12.772 18.6 18.6

Maximums atHigh Speed

Run Current - Amps 6.1 6.1 6.9 6.9 5.1 5.1 11.4 11.4 13.7 13.7 13.7 17.9 17.9

Start Current - Amps 8 8 8.6 8.6 7 7 13.6 13.6 17.1 17.1 17.1 22.1 22.1

Not to be used withoutreference to Combat

Air Flow - m³/hr 2500 2600 3100 3200 3250 3260 4480 5700 6200 6700 6800 9400 9400

Air Flow - ft³/min 1471 1530 1825 1883 1913 1919 2637 3355 3649 3943 4002 5533 5533

'D' RANGE

Required

Minimum Air Flow m³/hr 2500 2600 3100 3200 3250 3260 4383 4560 6200 6800 6800 9376 9376

ft³/min 1471 1530 1825 1883 1913 1919 2580 2684 3649 4002 4002 5519 5519

Pressure lossacross heat

exchanger atrequired air flow

mbar 0.43 0.43 0.43 0.43 0.43 0.43 0.43 0.43 0.43 0.43 0.43 0.43 0.43


9

4.4 Technical Data Table - CUHA, CUHB, CUHC and CUHD Manual Ignition Range

Appliance Category II 2H3+

Natural Gas Inlet Pressure 20 mbar (17 - 25)Propane Inlet Pressure 37 mbar (25-45)Butane Inlet Pressure 29 mbar (20-35)

*Gas rates corrected to standard conditions 1013.25 mbar 15°C

MANUAL IGNITIONMODEL NO

60 80 100 120 140 160 180 200 240

Heat Input Gross cv - kW 22.5 29.5 37 43 52 59 66.5 74 89

Heat Input Gross cv - Btu/hr 76770 100654 126244 146716 177424 201308 226898 252488 303668

Heat Input Net cv - kW 20.3 26.6 33.3 38.7 46.9 53.2 59.9 66.7 80.2

Heat Input Net cv - Btu/hr 69170 90689 113746 132191 159859 181379 204435 227492 273605

Approx. Heat Output - kW 17.78 23.31 29.23 33.97 41.08 46.61 52.54 58.46 70.31

Approx Heat Output - Btu/hr 60648 79517 99733 115906 140165 159033 179249 199466 239898

Number of Burners 4 4 5 6 7 8 9 10 12

NATURAL GAS

Injector size 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94

Injector marking 840 840 840 840 840 840 840 840 840

Burner Pressure - mbar 5.9 10 10.6 10.7 12.0 12.0 12.5 12.8 14.9

Burner Pressure - in. w.c. 2.4 4.0 4.2 4.3 4.8 4.8 5.0 5.1 6.0

*Gas Rate - m³/hr 2.14 2.81 3.53 4.10 4.96 5.62 6.34 7.05 8.48

Gas Rate - ft³/hr 75.70 99.30 124.50 144.70 175.00 198.50 223.80 249.00 299.50

Gas Valve Type S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova

0.820.054 0.820.054 0.820.054 0.820.054 0.820.054 0.820.054 0.820.054 0.820.054 0.820.054

Part No L 431 L 431 L 431 L 431 L 431 L 431 L 431 L 431 L 431

LPG GAS

Injector Size N/A 7 x .54 7 x .54 7 x .54 7 x .54 7 x .54 7 x .54 7 x .54 7 x .54

Injector marking N/A 250 250 250 250 250 250 250 250

Propane Inlet Pressure - mbar N/A 37.0 37.0 37.0 37.0 37.0 37.0 37.0 37.0

Propane Inlet Pressure - in. w.c. N/A 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8

*Propane Gas Rate m³/hr N/A 1.11 1.39 1.62 1.96 2.22 2.50 2.79 3.35

Propane Gas Rate kg/hr N/A 2.11 2.64 3.07 3.72 4.22 4.75 5.29 6.36

BUTANE

Butane Inlet Pressure - mbar N/A 29.0 29.0 29.0 29.0 29.0 29.0 29.0 29.0

Butane Inlet Pressure - in. w.c. N/A 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6

*Butane Gas Rate M³/hr N/A 0.84 1.06 1.23 1.49 1.69 1.90 2.12 2.55

Butane Gas Rate kg/hr N/A 2.15 2.69 3.13 3.78 4.29 4.84 5.39 6.48

Gas Valve Type N/A S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova

0.820.054 0.820.054 0.820.054 0.820.054 0.820.054 0.820.054 0.820.054 0.820.054

(No Regulator) (No Regulator) (No Regulator) (No Regulator) (No Regulator) (No Regulator) (No Regulator) (No Regulator)

Part No L 431 L 431 L 431 L 431 L 431 L 431 L 431 L 431

Gas Connection Size R ½ R ½ R ½ R ½ R ½ R ½ R ½ R ½ R ½


10

4.5 Technical Data Table - CUHA/A, CUHB/A, CUHC/A and CUHD/A Automatic Ignition Range

Appliance Category II 2H3+

Natural Gas Inlet Pressure 20 mbar (17 - 25)Propane Inlet Pressure 37 mbar (25-45)Butane Inlet Pressure 29 mbar (20-35)

*Gas rates corrected to standard conditions 1013.25 mbar 15°C

AUTOMATIC IGNITIONMODEL REFERENCE

/A 60 /A 80 /A 100 /A 120 /A 140 /A 160 /A 180 /A 200 /A 240 A 280 /A 300 /A 340 /A 380

Heat Input Gross cvkW

22.5 29.5 37 43 52 59 66.5 74 89 103 110 125 140

Heat Input Gross cvBtu/hr

76770 100654 126244 146716 177424 201308 226898 252488 303668 351436 375320 426500 477680

Heat Input Net cvkW

20.3 26.6 33.3 38.7 46.9 53.2 59.9 66.7 80.2 92.8 99.1 112.6 126.1

Heat Input Net cvBtu/hr

69170 90689 113746 132191 159859 181379 204435 227492 273605 316644 338163 384277 430390

Approx. Heat OutputkW

17.78 23.31 29.23 33.97 41.08 46.61 52.54 58.46 70.31 81.37 86.90 98.75 110.60

Approx. Heat OutputBtu/hr

60648 79517 99733 115906 140165 159033 179249 199466 239898 277634 296503 336935 377367

Number of Burners 4 4 5 6 7 8 9 10 12 14 15 17 19

NATURAL GAS

Injector size 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94 7 x .94

Injector marking 840 840 840 840 840 840 840 840 840 840 840 840 840

Burner Pressurembar

6.9 10.6 10.2 10.0 10.6 10.5 10.5 10.5 11.5 11.0 12.1 11.0 11.4

Burner Pressurein. w.c.

2.8 4.2 4.1 4.0 4.2 4.2 4.2 4.2 4.6 4.4 4.84 4.4 4.56

*Gas Rate - m³/hr 2.14 2.81 3.53 4.10 4.96 5.62 6.34 7.05 8.48 9.81 10.48 11.91 13.34

Gas Rate - ft³/hr 75.70 99.30 124.50 144.70 175.00 198.50 223.80 249.00 299.50 346.60 370.20 420.60 471.10

Gas Valve TypeS.I.T.

TandemS.I.T.

TandemS.I.T.

TandemS.I.T.

TandemS.I.T.

TandemS.I.T.Nova

S.I.T.Nova

S.I.T.Nova

S.I.T.Nova

S.I.T.Nova

S.I.T.Nova

Honeywell Honeywell

0.830.033 0.830.033 0.830.033 0.830.033 0.830.033 0.822.117 0.822.117 0.822.117 0.822.117 0.822.117 0.822.117VR 420AB 1002

VR 420AB 1002

Part No L 411 L 411 L 411 L 411 L 411 L 421 L 421 L 421 L 421 L 421 L 421 L 059B L 059B

LPG GAS

Injector Size N/A 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm 7 x .54mm

Injector marking N/A 250 250 250 250 250 250 250 250 250 250 250 250

PROPANE

Inlet Pressure - mbar N/A 37.0 37.0 37.0 37.0 37.0 37.0 37.0 37.0 37.0 37.0 37.0 37.0

Inlet Pressure - in. w.c. N/A 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8 14.8

*Propane Rate - m³/hr N/A 1.11 1.39 1.62 1.96 2.22 2.50 2.79 3.35 3.88 4.14 4.70 5.27

Propane Rate - kg/hr N/A 2.11 2.64 3.07 3.72 4.22 4.75 5.29 6.36 7.36 7.86 8.93 10.01

BUTANE

Inlet Pressure - mbar N/A 29.0 29.0 29.0 29.0 29.0 29.0 29.0 29.0 29.0 29.0 29.0 29.0

Inlet Pressure - in. w.c. N/A 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6 11.6

*Butane Rate - m³/hr N/A 0.84 1.06 1.23 1.49 1.69 1.90 2.12 2.55 2.95 3.15 3.58 4.01

Butane Rate - kg/hr N/A 2.15 2.69 3.13 3.78 4.29 4.84 5.39 6.48 7.50 8.00 9.10 10.19

Gas Valve Type N/AS.I.T.

TandemS.I.T.

TandemS.I.T.

TandemS.I.T.

TandemS.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova S.I.T. Nova Honeywell Honeywell

0.830.020 0.830.020 0.830.020 0.830.020 0.822.117 0.822.117 0.822.117 0.822.117 0.822.117 0.822.117VR 420AB 1002

VR 420AB 1002

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

(NoRegulator)

Part No L 413 L 413 L 413 L 413 L 421 L 421 L 421 L 421 L 421 L 421 L 059B L 059B

Gas ConnectionSize R ½ R ½ R ½ R ½ R ½ R ¾ R ¾ R ¾ R ¾ R ¾ R ¾ R 1 R 1


11

4.6 Gas Controls - Automatic IgnitionGas control valves fitted are dependent upon the model, each giving the same control elements as follows. See Page 40, Figure 16 through Page 41, Figure 19.

4.6.1 Main Gas BurnerThe main gas valve contains

• Gas pressure regulator.

• Two automatic shut off valves. When commissioned as defined on Page 38, Section 11 through Page 43, Section 11.12 the valves will have a step opening operation on the main gas. Settings of the valves are given on Page 42, Section 11.4.2 and in the tables on Page 9, Section 4.4 through Page 10, Section 4.5.

4.6.2 Pilot Gas Burner (Models 340 to 380 only)There is one solenoid valve to control the pilot burner gas supply which is designed to operate at inlet pressure.

4.7 Gas Controls - Manual IgnitionThe gas valve contains

• Main gas regulator.

• Safety gas valve controlled by the thermocouple.

• Solenoid valve to operate the main gas.

• Manual control knob and piezo electric igniter.

4.8 Main FanThe main air moving fan(s) fitted to these heaters are operated automatically by the fan thermostat within the combination fan/limit thermostat. When suitably connected to site wiring (See Page 21, Section 10) the fan(s) may also be used for distributing unheated air.

4.9 Limit ThermostatsThere are two limit thermostats on these heaters to protect them from overheating, should the fan fail. One is within the combination thermostat and the second is on the side of the heater towards the rear of the heater. NOTE: On models 340 and 380 B & C versions there is a further secondary limit thermostat protecting the third fan unit.

4.9.1 Honeywell Combination Fan/Limit Thermostat (See Page 12, Figure 5)The combination fan/limit thermostat is a dual function control and safety device. Two of these are fitted to CUHD versions, the second one is on the inlet spigot at the rear of the heater.

Fan ThermostatThe fan thermostat controls the operation of the main fan during the heater operation. It also ensures that the main fan continues to run after the burner turns off.The white button on the fan thermostat should be pulled to its “out” position for normal operation. In the “pushed in” position the fan will run continuously.

Limit ThermostatThe limit thermostat operates in overheat conditions caused by insufficient air passing over the heat exchanger. This is a manual reset device and is reset by pressing in the red reset button on the thermostat.

4.9.2 Second Limit ThermostatThis is a manual reset device - See Page 7, Section 4.2.NOTE: On CUHB and CUHC models 340 and 380 there are two of these fitted.To reset this thermostat:

1. Remove the screw on cover of the thermostat where it protrudes from the cabinet side.

2. Push in the button in the centre of the thermostat.

3. Replace the cover.

4.10 Thermocouple Interrupter RelayManual ignition heaters are fitted with a thermocouple interrupter relay to interface between the limit thermostats and the thermocouple. The limit thermostats provide a constant voltage to the coil connections making the relay permanently energised. On interruption of the electrical supply to the relay, the contact opens causing the safety valve to close. The pilot will then need to be manually lit.

4.11 Automatic Ignition - Burner Control Box

4.11.1 Description of Burner Control BoxThe fully automatic gas burner fitted to all CUHA/A, CUHB/A, CUHC/A and CUHD/A models is controlled by a Satronic DKG 972 or a Honeywell S 4563 control box. This control ensures the safe start and stop sequence and also monitors the safe presence of a flame. See Page 56, Figure 26.


12

Figure 5: Combination Fan/Limit Thermostat

Figure 6: Honeywell Control

Dial

Limit Hand

Fan Off Hand

Fan On Hand

Fan Terminals

Manual Fan Switch

(White)

BREAK-OFF LINKMUST BE REMOVED

Limit Terminals

Limit StatManualReset Button(Red)

Push in Lock

Wire to Controlled Equipment

Push Screwdriver inand hold to release

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SECTION 5: HEATER INSTALLATION

13

SECTION 5: HEATER INSTALLATION5.1 General Heaters are designed for installation where by the bottom panel of the heater is between 2.75m and 3.75m above the floor.

5.2 HandlingAll CUH range heaters are supplied secured to a wooden pallet and shrink wrapped.Use the pallet to support the heater during handling and installation.

5.3 Shelf Mounting and Suspension

The bottom panel is not intended to support the weight of the heater. For typical suspension See Page 13, Figure 7.

Figure 7: Suspension Methods

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14

SECTION 6: FLUE INSTALLATION6.1 Flue Installation

Flues must be correctly sized for the model. See Page 6, Section 4.1. Flues should be assembled as on Page 5, Figure 2, on Page 5, Figure 3 and Page 14, Figure 8 through Page 15, Figure 11. The joints between the flue and the roof or wall must be properly sealed. If the flue passes through a wall or ceiling of combustible material it must be enclosed by a sleeve of non-combustible material and be separated from the sleeve by at least a 25 mm air gap.

Flues must be adequately supported so that the heater does not bear the weight of the flue.For straight and offset flue termination See Page 5, Figure 2 and Figure 3. 90° bends and horizontal pipe must not be used in flues. 135° bends are used to offset the flue as in Figure 3.

Figure 8: Guy Wire Figure 9: Socket Direction

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15

Figure 10: Flue and Roof Detail Figure 11: Flue and Heater Spigot Joint Detail

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6.2 Models 340 and 380 only

The models 340 and 380 heaters are provided with two outlet spigots on top of the heater and a flue assembly to combine these two flue outlets into a single vertical flue.

For flue assembly See Page 16, Step 6.2.1 and Step 6.2.2.

The remainder of the vertical flue is then installed from the spigot at the top of the assembly in accordance with the instructions for all other models.

Step 6.2.1 Flue assembly for models 340 and 380 only.

Step 6.2.2 Fitting Flue assembly to heater for models 340 and 380 only.

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SECTION 7: AIR SUPPLY

17

SECTION 7: AIR SUPPLY7.1 Air SupplyIt is important to ensure that there is adequate air supply at all times for both combustion and heating requirements.

7.1.1 Isolated Equipment RoomsVentilation must prevent the isolated equipment room temperature from exceeding 32°C as well as prevent any negative air pressure within the room. See Page 19, Figure 12. Any isolated equipment room containing air heaters will require permanent air vents direct to outside air in compliance with local codes

Where natural ventilation is used, suitable permanent openings at low and high level, communicating directly with the outside air, must be provided.

Where mechanical ventilation is used, extract rate must be 5% - 10% less than the inlet rate. The mechanical ventilation must be interlocked with the burner on the CUH heater.

7.1.2 Heaters Installed Within the Heated SpaceWhere the volume of the heated space is greater than 4.7 m3 per kilowatt of total rated heat input and the air change rate is at least 0.5/h, additional high and low level ventilation will not be required.

For a building having an air change rate less than 0.5/h, low level ventilation will be necessary in accordance with local codes.

7.2 Building VentilationWhere ventilation is required air must be taken from an outside point where it is not likely to be contaminated.


18

SECTION 8: OPTIONAL HEATER CONFIGURATIONS8.1 Distribution Ductwork for CUHB, CUHC and CUHD HeatersCUHC range heaters have the fans enclosed so that the heater may be connected to inlet ducting.

CUHD range heaters are supplied with inlet and outlet duct spigots for mounting the heater into a customer designed duct system for use with an external fan system.

It is important when ducted systems are required that only the spigots and flanges produced and fitted by Roberts-Gordon are used at the heater. See Page 5, Figure 4 and Page 19, Figure 13. It is recommended that flexible duct connectors are used to reduce duct born noises.

When installing heaters onto ducting use a 60 second time delay relay to force the fan to run.Do not rely on the fan thermostat to turn it on. See suggested scheme on Page 22, Figure 10.3.Any such device must be in parallel with the fan thermostat so that the fan run-on operation will still operate. CUHD heaters are fitted with two combination thermostats, at the front and in the rear inlet spigot for this purpose

Contact Roberts-Gordon Europe Ltd. Design Department for recommendations regarding duct resistance and design. Tel: +44 (0) 1902 494425

8.1.1 CUHD HeatersFor CUHD heaters it is essential that the airflow in the duct system is at least that specified in the Data Sheet on Page 8, Section 4.3 and in the correct direction across the heat exchanger as indicated by the arrow on the heater. Higher air flows are permitted, but will cause a lower exiting air temperature. It is recommended that the fan is positioned to blow the air through the heat exchanger.

The duct must be designed as described on Page 18, Section 8.1 and on Page 5, Figure 4 to ensure that there is a homogenous air flow across the whole of the heat exchanger.

Failure to provide a suitable air flow properly distributed across the heat exchanger will reduce the life of the heat exchanger.

The fan motor or its control must contain a method of overload protection. When installed remote from the heater the fan must be supplied via a local electrical isolator positioned and properly labeled to prevent inadvertent operation.

SECTION 8: OPTIONAL HEATER CONFIGURATIONS

19

Figure 12: Heaters installed in isolated equipment rooms.

Figure 13: CUH C or D Heaters with Inlet/Outlet Duct Spigots and Flange.

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20

SECTION 9: GAS PIPING

A gas meter is connected to the service pipe by the Gas Supply Company. An existing meter should be checked, preferably by the Gas Supply Company to ensure that the meter is adequate for the rate of gas supply required.

Connect the heater to the gas supply ensuring that the final connections are as follows:

• Gas supply pipe work is run in medium or heavy gauge tubing to National Standards terminating as shown on Page 20, Figure 14.

• An isolating valve and union connection should be used and fitted into the supply adjacent to the heater.

• For suspended heaters use an approved metal flexible connection between the isolating valve and the heater. To reduce pressure loss, use one pipe size larger that the supply gas pipe.

IMPORTANT - the complete installation must be purged and tested for gas soundness in accordance with National Standards.

L.P.G.For L.P.G. applications each heater must be provided with the gas inlet pressure closely controlled to 37 mbar for Propane (G31) or 29 mbar for Butane (G30). A suitable regulator controlling the inlet pressure to each heater will be required for this.

Figure 14: Gas Connection with Stainless Steel Flex Connector

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Insure all joints aregas tight.

SECTION 10: WIRING AND ELECTRICAL INFORMATION

21

SECTION 10: WIRING AND ELECTRICAL INFORMATION10.1 Electrical SupplyAll heater models need a constant 230 volt 50 Hz single phase supply connected to terminals L, N & Earth.Polarity "L & N " must be correct.For automatic ignition versions the voltage between N and Earth must not exceed 15v.All heaters and controls must be correctly earthed. All external wiring must comply with the relevant local codes.External controls must have the same constant 230v 50Hz supply.

An isolator with a contact separation of at least 3 mm on all poles must be installed adjacent to, but not fixed to the heater to disconnect all supplies to the heater and any remote control.

The final connection to the heater should be made in flexible conduit to the main terminal block on the side of the heater using 1 mm2 cable on all models.

Models Fuse Size

CUHA, CUHA/A all models 5 Amp.

CUHB, CUHB/ACUHC, CUHC/A up to 300 10 Amp.

CUHB, CUHB/A, CUHC,CUHC/A from 340 to 380 20 Amp.

CUHD and CUHD/A models must have the external fan, or its control connected to Terminal 1 so that the fan run-on function at close down operates correctly.See Page 22, Section 10.4.

10.2 Remote ControlsThe heaters are designed to be operated by controls installed remote from the heater. See Page 22, Section 10.3.

10.2.1 Burner ControlsControls to operate the burner must be voltage free contacts connected between terminals 2 & 3 of the main terminal block on the side of the heater.

10.2.2 Siting Room Thermostats or Roberts-Gor-don Control A room thermostat or Roberts-Gordon control should be mounted on a wall or column at a height of approximately 1.5 metres from the floor to measure the ambient temperature. It should be clear of cold draughts and the direct path of warm air from the heater.

10.2.3 Remote Frost ThermostatWhere a frost thermostat is required to override the operation of a time switch during its "off" periods, connect to terminals 2 and 3 in the main terminal block on the side of the heater. Locate within the heated space adjacent to the most vulnerable equipment that requires protection.See Page 22, Section 10.3.

10.2.4 Remote Fan ControlsThe fan will operate automatically providing there is a constant 230v supply to the main terminals. A switch or control wired between terminals L & 1 in the terminal block at the side of the heater will allow external control of the fan(s).The fan may be controlled to operate continuously from an external control, with the burner cycling on and off, providing that the fan run-on at close down is not impaired.

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10.3 CUH Individual Controls (all models)

10.4 CUHD External Motor Alternative Wiring (all models)

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10.5 CUHA Wiring Diagram

10.6 CUHB & CUHC Wiring Diagram (60-160)

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10.7 CUHB & CUHC Wiring Diagram (180-240)

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10.8 CUHD Wiring Diagram (all models)

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10.9 CUHA/A Wiring Diagram (60-240) Satronic

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SECTION 11: COMMISSIONING THE HEATERInstallation, service and annual inspection of heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment.

Read this manual carefully before installation, commissioning, operation, or service of this equipment.

11.1 Pre Commission Checks All pre commission checks must be carried out before lighting the heaterEnsure that the heater and all controls are suitable for the gas, pressure and electrical supply to which they are to be connected.

11.1.1 Louvers The air delivery louvers need to be set during commissioning to give the required air distribution.To do this each louver must be twisted around its axis, raising the lower edge forward. The minimum gap is 30mm. See Figure 15.

NOTE: The louvers are designed to be set once, but will allow for occasional readjustment.Frequent adjustment will damage the axis system and require louver assembly replacement.

Figure 15: Setting Louvers

11.1.2 Electrical ChecksAll pre commission checks must be carried out before commissioning the heater.

1. Check that all site wiring is connected in accordance with the appropriate wiring dia-grams on Page 21, Section 10 through Page 37, Section 10.24.

2. Check the correct fuse size is fitted;See Page 21, Section 10.1.

11.1.3 Polarity Test

11.2 Gas SupplyAll aspects of the gas installation including the gas meter must be inspected, tested for soundness and purged in accordance with local codes.Ensure that the air is fully purged from the heater inlet pipe up to the main gas valve inlet test nipple.

11.3 Mechanical Checks1. Check that the fan(s) are free to run and

delivery louvres are turned to give required air deflection.

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2. Check that the flue is installed in accordance with these instructions and local regulations.

3. Check that the settings of the Combination Fan/Limit thermostat are correct - see below.

NOTE: The second limit thermostat is preset and sealed at the factory and is not adjustable.

Front Combination Thermostat (All Models)

Rear Combination Thermostat on CUHD... Only

Always refit the cover and tighten the cover screw after adjustments.

To continue with the Commissioning follow Page 39, Section 11.4 for Automatic Ignition models or Page 42, Section 11.5 for Manual Ignition models. Then continue on Page 43, Section 11.6 for all appliance types

11.4 Automatic Ignition Unit Heaters 11.4.1 Before Operating the HeaterTo ensure that all the controls are in safe working order, operate the heater for the first time with the main gas valve turned off.

Models 340 & 380 (with a separate pilot)1. Unplug the electrical plug from the main gas

valves.

For Models 340 & 380 1. The pilot flame will ignite when pilot gas valve

opens. If the flame does not ignite then the con-trol will go to lockout.

2. Wait one minute, then press in the control box reset button, or the remote reset button if fitted, and repeat until the pilot flame ignites.

NOTE: At the first firing of the heater it may be necessary to repeat several times to purge the remaining air from the gas train.

3. There is no adjustment for the pilot burner. Once the pilot flame has ignited it will be moni-tored by the flame probe and should remain on until the controls turn it off.

4. Turn off the burner at the external control and refit the electrical plug(s) to the main gas valve.

For All other Models 1. Turn off the gas isolating valve

2. Using the installed external control, turn on the burner. The automatic sequence will now begin as described on Page 56, Section 15.2.1, Fig-ure 26 and Page 44, Section 12, Figure 20.

There will be no ignition of the burner and lockout will occur, which proves the controls are operating correctly.

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Figure 16: S.I.T. Tandem 0.830.033 Gas Valve (Natural gas) 0.830.020 Valve (L.P.G)

Figure 17: S.I.T. Nova 0.822.177 Automatic Ignition Gas Valve

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Description Part NumberS.I.T. Tandem 0.830.033 Automatic Ignition Natural Gas Valve L411S.I.T. Tandem 0.830.020 Automatic Ignition LPG Gas Valve L413

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Figure 18: S.I.T. Nova 0.820.054 Manual Ignition Gas Valve

Figure 19: Main Gas Valves for Models 340 and 380

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The main gas control valve used on all versions of the models CUHA/A, CUHB/A, CUHC/A and CUHD/A 340 and 380 is the Honeywell VR 420AB 1002 combination gas valve. This control contains two main safety shut off valves and burner pressure regulator.

Honeywell VR 420AB 1002 Main gas valve

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11.4.2 Commissioning the Gas Valves Natural Gas11.4.2.1 Check Burner Gas Pressure

1. Remove the screw cover of the outlet (burner) pressure test point and connect a manometer.

2. With the burner firing, measure the pressure on the manometer. To adjust the burner pressure, remove the regulator cover from the valve and turn the regulator adjustment screw to set the required burner pressure as stated in the Tech-nical Data Tables on Page 9, Section 4.4 through Page 10, Section 4.5.

NOTE: If the correct burner pressure cannot be reached, then check the inlet pressure to the valve, with the burner firing. See Technical Data Tables on Page 9, Section 4.4 through Page 10, Section 4.5 for pressure requirement.

Do not continue to adjust the regulator if the pressure is not changing.

If the inlet pressure is too low to allow correct burner setting, then gas pressure must be corrected before completing the commission.

Step Opening (Direct Main Flame Ignition)It is important that the step opening is adjusted correctly.This ensures that the burner ignites smoothly and quietly.

S.I.T. Tandem valves Models 60 to 1401. Turn off the burner and wait one minute for the

valve to settle.

2. Remove the plastic cover from the step open-ing breather port. See Page 40, Figure 16. Block this port with a finger, to keep the valve at step open level. Turn on the burner again and use the step opening adjuster to set the step opening pressure to approximately 2.5 mbar.

3. Refit the plastic plug to the breather port.

S.I.T. Nova and Honeywell valvesDo not attempt to adjust step opening on these valves.

Check Gas Rate1. After burner pressure adjustment, allow the

heater to operate for at least 15 minutes and then re-check settings.

2. Remove the manometer and refit all covers to the valve.

3. Check gas flow rate at gas meter.

11.4.3 Commissioning the Gas Valves Liquid Petroleum Gas (L.P.G.)

1. In all cases the gas valves for L.P.G either have no regulator or have the regulator set to maxi-mum. See Page 50, Section 14.

2. Set the inlet pressure to the gas valve to 37 mbar for G31 (Propane) or 29 mbar for G30 (Butane).

NOTE: The appliance will operate safely between 25-45 mbar for G31(propane) or 20-35 mbar for G30 (butane). The correct heat input is at the specified inlet pressure. No further adjustment is necessary.

11.5 Manual Ignition Unit HeatersAll CUH manual ignition unit heaters are controlled by an S.I.T Nova 0.820.054 multifunctional gas valve. See Page 41, Figure 18.

1. Remove the electrical plug from the multifunc-tional gas valve to ensure that main gas cannot be released.

2. Ignite the pilot: Press in the manual control knob of the gas valve and turn counter-clock wise to the star symbol. See Page 46, Figure 22. Press the knob in and hold while intermit-tently pressing and releasing the piezo ignition device to create the spark ignition.

3. Once the pilot flame has lit, continue to hold in the control valve knob for an additional 20-30 seconds, then release. The pilot flame should remain on. If the pilot fails to light, or goes out, wait 3 minutes before trying to light the pilot again.

4. Once the pilot flame has been established it will remain on constantly unless the gas or electricity supplies are interrupted or the limit thermostats operate.

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To Operate the Main BurnerReplace the electrical plug onto the gas valve. Press in slightly and turn the valve control knob a quarter turn counter-clockwise to the "flame" symbol. With the external controls in an on position and calling for heat the main burner will now fire.

Carry out the checks of burner settings as described on Page 42, Section 11.4.2.1.

11.6 Commissioning Tests - (all models) Spillage TestWith the main burner operating for at least 15 minutes carry out a spillage test on the draught diverter in accordance with local codes. Ensure that all doors and windows in the area are closed and that any extract fans are turned ON.

If spillage is occurring then corrective action MUST be taken. See Page 3, Section 3 and Page 14, Section 6 for design of flues and Page 17, Section 7 for air supply.

11.7 Combustion Testing - (all models)The only adjustment to alter combustion performance is burner pressure, combustion quality must be tested to prove correct heater operation. Incorrect results will indicate faults with the installation or appliance.

Combustion testing must be carried out with all covers in place. The flue gas is sampled in the flue, within 1 metre of the heater. The values of CO2 (Carbon Dioxide) should be between 5.5% and 6.5%. CO (Carbon Monoxide) should be no more than 0.005% (50 PPM). Temperature rise of the flue gases above ambient should be approximately 160°C to 180°C.

11.8 Pilot Drop-Out Test - Manual Ignition ModelsCarry out the Pilot Drop-Out Test as described on , Section 13.5 and ensure a positive result.

11.9 Turning Off the Heater - (all models)Set the external controls to the off position and the main burner will stop.The fans will run until they are stopped automatically by the fan thermostat. Do not use the electrical isolator for shutting off the burner. This will switch off the fan prematurely and may damage the heat exchanger.11.10 External ControlsExternal Controls may include time switch, room thermostat and manual switch.Operate each control to ensure that they function correctly. Set the time

switch (if fitted) and room thermostat to the users’ requirements.

11.11 Complete the InstallationEnsure that all covers are fitted correctly and all test points are properly sealed.

11.12 Instruction to the UserExplain the controls of the heater to the user including how to turn it on and off, using the controls fitted on site. Give this manual to the user.Ensure that the user is shown and understands the user instructions on Page 44, Section 12 through Page 47, Section 12.9 and all warnings defined in this manual.

Do not use electrical Isolator for control of heater. Electrical Isolator will switch off the fan. Heat exchanger will be damaged. Warranty will not cover damage to the heat exchanger if operated improperly.


44

SECTION 12: USER INSTRUCTIONS12.1 User InstructionsAutomatic IgnitionThe CUHA/A, CUHB/A, CUHC/A & CUHD/A ranges of heaters are fully automatic and operate from the external controls fitted on site. The only user controls at the heater are the:Burner lockout reset button................See Page 45, Section 12.4.1Fan run button ...........See Page 44, Section 12.3.1Limit thermostat reset ..........................See Page 44, Section 12.3.1Second limit thermostatreset button ...............See Page 45, Section 12.3.2(Models 340B/C & 380B/C have two second limit thermostat reset buttons.)

Manual IgnitionThe CUHA, CUHB, CUHC & CUHD ranges of heaters are manual ignition of the pilot, but operate automatically from the remote controls fitted on site.The user controls on these heaters are:Main gas valve controls for lighting the pilot andmain burner ................ See Page 45, Section 12.7.1..................................... and See Page 46, Figure 22Fan run button ............ See Page 44, Section 12.3.1Limit thermostat reset............................ See Page 44, Section 12.3.1Second limit thermostatreset button................. See Page 45, Section 12.3.2

Do not use electrical Isolator for control of heater. Electrical Isolator will switch off the fan. Heat exchanger will be damaged. Warranty will not cover damage to the heat exchanger if operated improperly.

12.2 Heater OperationWhen the heater has been switched on by the remote controls installed on site the main burner will automatically turn on.

For automatic ignition heaters, the burner control box will control the safe ignition of the pilot and main flame.

For manual ignition, the pilot flame must be manually ignited and constantly lit so that the external controls may operate the main burner.

All heaters require a constant gas and electricity supply which must not be interrupted during the normal operation of this heater.

Figure 20: Heater Operating Sequence

12.3 Common User Controls (all models)12.3.1 Combination Fan/Limit ThermostatThe Combination Fan/Limit Thermostat is located on the top right hand side of the heater. See Page 7, Section 4.2.This control ensures the heater does not blow cold air in the normal heating cycle and protects the heat exchanger against overheating.

Figure 21: Fan/Limit Thermostat

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The combination fan/limit thermostat is preset during commissioning.See Page 38, Section 11.3NOTE: To reset the heat exchanger must be cool.

If the air flow is reduced due to power failure the limit thermostat will cause the burner to lockout.

SECTION 12: USER INSTRUCTIONS

45

12.3.2 Secondary Limit Thermostat

12.4 Automatic Ignition User Controls

12.4.1 Burner Lockout Reset ButtonThe red warning light will illuminate when the control has gone to lockout. This may be caused by flame failure.After lockout wait three minutes before attempting to reset the control.Press the reset button on the side of the heater near the warning lights, or the remote reset if fitted.

12.5 Automatic Ignition Lighting Instructions For types CUHA/A, CUHB/A, CUHC/A and CUHD/A only. (See Page 45, Section 12.7 for lighting manual ignition heaters.)

12.5.1 To Turn On Heater1. Ensure that the electrical and gas supplies to

the heater are on. Check that the on site con-trols are “ON”.

NOTE: The thermostat must be above the ambient temperature for the heater to operate.

2. The automatic firing sequence will begin as described on Page 56, Figure 26. The heater will now operate automatically under the con-trol of the on site controls. Following long shut down periods, the control may go to lockout. See Page 45, Section 12.4.1.

12.5.2 To Turn the Heater Off Set the installed remote controls to the “OFF” position. The burner will turn off immediately.The fan will continue to run for a few minutes. To restart turn the control used above to “ON”.

12.6 Manual Ignition User Controls12.6.1 Multifunctional Gas ValveThe gas valve fitted to all manual ignition unit heaters is shown on Page 46, Figure 22. The gas valve is used to control the gas supply while lighting the pilot flame by hand.Follow the instructionson Page 45, Section 12.7 to light the pilot and operate the main burner.

12.7 Manual Ignition Lighting InstructionsFor types CUHA, CUHB,CUHC and CUHD only.(See Page 45, Section 12.5 for lighting automatic ignition heaters.)

12.7.1 Ensure that the electrical and gas supplies to the heater are on. Check that the remote controls are set to “OFF”.

To Light Pilot (See Page 46, Figure 22.)1. Press in the manual control knob of the gas

valve and turn counter-clockwise to the star symbol.

2. Press the knob fully in and hold while pressing and releasing the piezo ignition device to create the spark ignition.

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There are two of these thermostats on Models 340B/C and 380B/C which are sited on the rear panel below the fans. These are hand reset devices to give further protection against fan failure.NOTE: To reset the heat exchanger must be cool.

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3. Once the pilot flame has been lit (visible through the rear panel near the gas pipe to the burner) continue to hold in the control valve knob for 30 seconds, and then release. The pilot flame should now remain on.

4. Once the pilot flame has been established it will remain on providing that the gas or electricity supplies are not interrupted and the limit ther-mostats do not operate.

To Operate The Main BurnerPress in slightly and turn the valve control knob a quarter turn counter-clockwise to the "flame" symbol.Set the external controls to the "ON" position.The thermostat must be above the ambient temperature for the heater to operate.The main burner will now operate automatically providing that the pilot flame remains alight.

Step 12.7.2 To Turn the Heater Off Set the external controls to the “OFF” position. The burner will turn off immediatelyThe fan will continue to run for a few minutes.The heater will remain off until the controls are turned on again.

12.8 Simple Fault Finding (all models)Some possible reasons for the heater not operating are:

1. Gas supply not turned ON.

2. Electricity supply not turned ON.

3. The time and/or temperature controls are not “ON”.

4. One or both of the Limit Thermostats may have operated. This may be caused by an interrup-tion of the electrical supply or failure of the distribution fan.

If the Limit Thermostats persistently operate, there is a fault which must be investigated by a contractor qualified in the installation and service of gas-fired heating equipment.

12.8.1 Simple Fault Finding - Automatic Ignition HeatersIf the burner fails to ignite for any reason, it will go to lockout. This will be indicated by the red light on the heater or at the remote indicator (if fitted).

1. Wait one minute to reset. Press in and release the lockout reset button. If a remote reset is not fitted access this button through the hole in the electric box cover near the indicator lights.

Lockout should not occur during normal operation of the heater and indicates there is a fault condition which must be corrected.

Figure 22: S.I.T. Nova Valve for Manual Ignition, Operation

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OFF Position START Position BURNER RUNPosition

Press in and hold to light pilot

Press in and turnto start

Press in and turnto run burner

Press in andturn to stop

Press in andturn to stop

SECTION 12: USER INSTRUCTIONS

47

12.8.2 Simple Fault Finding - Manual Ignition Heaters

1. Ensure that the pilot flame is lit. See Page 45, Section 12.7.

2. Ensure that the control knob of the gas valve is turned to the main flame position.

3. If the pilot flame fails regularly, ensure that the electrical supply to the heater is not being inter-rupted. Electrical interruption for even a few seconds will cause the interrupter relay to turn off the pilot.

12.9 Service RequirementsThis heater will require servicing annually. When operating the heater in a dirty or dusty area, more frequent service may be necessary. The service must be done by a registered installer/contractor qualified in the installation and service of gas-fired heating equipment or your gas supplier in accordance with the requirements of this manual.

For service, contact your Heating Supplier.The heater cabinet may be cleaned using a damp cloth and domestic detergent.Do not use excessive water or abrasives.

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SECTION 13: SERVICING13.1 Servicing InstructionsAfter commissioning, the heater will require maintenance to be carried out annually. If the heater is used in a dirty or dusty area, more frequent maintenance may be necessary.

Installation, Service and Annual Inspection of heater must be done by a contractor qualifiedin the installation and service of gas-fired heating equipment.

NOTE 1: After any maintenance or repair work always test fire the heater in accordance with the commissioning instructions on Page 38, Section 11 through Page 43, Section 11.12 to ensure all safety systems are in working order before leaving the heater to operate. Minor faults may be traced by using the troubleshooting charts on Page 53, Section 15 through Page 59, Section 15.6.

NOTE 2: Check all gas pipes and pipe joints to ensure there are no cracks or gas leaks. Any cracks in the pipes or pipe joints must be repaired.

13.1.1 Burner MaintenanceBurner maintenance is similar for manual and automatic ignition heaters. Where there is a significant difference, the two types are referred to separately:

1. Remove the Burner Assembly.See Page 60, Section 16.1 through Page 62, Section 16.3.

2. Check condition of the pilot burner (where fitted), ignition electrode and flame probe (for automatic), or thermocouple (for manual) as appropriate. Clean off any deposits which may have been formed on the thermocouple or flame probe. Replace as necessary.

3. Check that the pilot gas pipe (where fitted) is clear of any deposits and that there are no cracks or gas leaks. Any cracks in the pipes or pipe joints must be repaired. See Page 62, Section 16.3.

4. Clean any deposits from the main burner which may have formed in the injectors or venturi of the burner. See Page 60, Section 16.2.

5. Check the condition of the thermal insulation at the bottom of the burner compartment and replace if necessary. The foil face of this insulation must be complete and unbroken.

13.2 Fan/Motor Assembly Maintenance (all models)The main fan bearings are permanently sealed and do not need lubrication. Before cleaning, turn off gas and electrical supply. Remove the fan guards and use a small brush or duster to clean the fan blades from each side of the fan(s). Replace fan guards when done.

13.2.1 For CUHB & CUHC Centrifugal Fan ModelsCUHB and CUHC models are fitted with thermally protected three speed fans. The General Technical Data Table (See Page 8, Section 4.3) indicates the number of fans and the standard running speed for each model.For CUHC models, the fans may be accessed via the removable panels in the top, bottom and sides of the inlet spigot compartment as required.

Do not operate at higher speeds than the original setting on the heater without prior consultation with Roberts-Gordon. The "HIGH" speed option is available to give the normal required air flow against higher static pressures and is not intended to be operated free blowing or against low resistance. Use of the fans under these conditions may cause the fan thermal overload to operate and the fan thermostat to cycle.

Where two or three fans are fitted they must all be operated at the same speed. They will be switched using a fan contactor built into the heater. See Page 64, Section 16.6.2.

13.3 Heat Exchanger MaintenanceThe heat exchanger will remain clean unless a problem has developed with combustion.Inspect the heat exchanger. Look for signs of overheating at the lower edges which may indicate burner over firing or persistently low air flows. Any deposits in the heat exchanger may be removed

with a small flue brush and a vacuum cleaner after removing the burner tray.

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SECTION 13: SERVICING

49

13.4 Gas Control Valve Maintenance (all models)No regular maintenance is required on these devices. To change gas control valves, See Page 60, Step 16.1.2 and Page 63, Section 16.4.Do not repair or disassemble on site.Replace faulty gas valves with genuine ROBERTS GORDON® replacement parts.

13.5 Manual IgnitionPilot Drop Out Test To check that the flame failure device operates correctly:

1. With the pilot flame lit continuously for at least ten minutes, turn off the gas isolating valve and watch the pilot flame.

2. Measure the time taken from the pilot flame going out until the gas safety valve operates, which can be felt and heard as a dull click. The time must be less than 60 seconds.

If the test fails and more than 60 seconds elapse before the safety valve operates, the thermocouple must be replaced. Use only genuine ROBERTS GORDON® replacement parts, See Page 62, Section 16.3.

Repeat the test to confirm a positive result.


50

SECTION 14: CONVERSION BETWEEN GASES14.1 GeneralNOTE: All CUH 60 models can only be operated on Natural Gas. Do not operate these models on L.P.G. All versions of the heaters use the same main burner bars and pilot burners.

Natural GasAll natural gas versions use the same main burner injectors, marked 840, and pilot injectors (where fitted) marked 34. The gas valves vary according to the models size and method of control. In all cases the valve contains a gas pressure regulator to allow for setting of the burner pressure.

L.P.G.All L.P.G. versions use the same main burner injector, marked 250, and pilot injectors (where fitted) marked 19. The gas valves vary according to the models size and method of control. If the gas valve contains a gas pressure regulator, it is disabled. The correct operation of the heater depends on the close control of the gas inlet pressure to the appliance.

14.2 Burner ConversionTo convert the burner assembly from one gas to the other is the same for all types of heater.

1. Remove the burner tray as on Page 60, Section 16 and remove all of the main burner injectors.

2. Replace with the injectors for the new gas.

3. Remove the pilot burner assembly where fitted, keeping the flame monitor, and spark electrode.

4. Fit the new pilot burner injector following the instructions on Page 62, Section 16.3.4.

14.3 Gas Valves - Automatic IgnitionThere are three types of valves used for this range of heaters. See Page 9, Section 4.4 through Page

10, Section 4.5, Technical Data Tables for part numbers and specification numbers.

14.3.1 Tandem Range ValvesTandem range main gas valves cannot be converted between gasses as they are constructed either with or without a governor. These valves must be changed for the correct type as listed in the data tables on Page 8, Section 4.3 through Page 10, Section 4.5.

14.3.2 Nova Range ValvesNova range main valves may be converted to operate with or without a burner gas pressure regulator.To Convert Nova valve from Natural Gas to L.P.G. (See Page 51, Figure 24).

1. Remove the dustcap of the pressure regulator.

2. Completely unscrew the governor spring assembly and remove it complete with its spring.

3. Replace the governor spring assembly and dustcap with the exclusion screw.

4. Tighten the exclusion screw into the body of the regulator until it stops. The regulator is now dis-abled. The step opening feature of the main valve will still operate.

To Convert Nova Valve from L.P.G. to Natural Gas


2. Completely unscrew the exclusion screw and remove it.

3. Replace the exclusion screw with the governor spring assembly. Adjust for appropriate burner pressure. See Page 10, Section 4.5.

4. Screw in dustcap.

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��"�A�� "�A��Description Part Number S.I.T. Part NumbersPilot Bracket B186 0.140.020Pilot Burner Injector L.P.G. Marked 19 B088 0.977.148Pilot Burner Injector Nat. Gas Marked 34 B184 0.977.103

SECTION 14: CONVERSION BETWEEN GASES

51

Figure 24: Conversion of Nova Family Valve

14.3.3 Conversion of Honeywell Valve to L.P.G.1. Remove the dustcap of the pressure

regulator.

2. Screw the regulator adjusting screw clockwise down fully.

3. Replace the dust cover tightly and apply paint or similar across the mating face of cover and valve.

The regulator is now out of action and the heater must be supplied with a gas pressure closely controlled at 37 mbar for Propane or 29 mbar for Butane.

14.3.4 Conversion of Honeywell Valve from L.P.G. to Natural Gas


2. Unscrew the regulator adjusting screw counter clockwise to a halfway position before lighting the appliance and further adjusting this screw to give the appropriate burner pressure shown in the table on Page 10, Section 4.5.

3. Replace the dustcap.

Figure 25: Conversion of Honeywell Gas Valve for L.P.G.

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Description Part NumberExclusion Screw L425Governor Spring Assembly L436Dustcap L437

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14.4 Conversion of Manual Ignition ValvesAll CUH range manual ignition unit heaters use an S.I.T Nova multifunctional gas valve.

Nova Range ValvesNova range main valves may be converted to operate with or without a burner gas pressure regulator.

To convert Nova valve from Natural Gas to L.P.G. (See Page 51, Figure 24).

1. Remove the cover of the pressure regulator.

2. Completely unscrew the regulator adjusting screw and remove it complete with its spring.

3. Replace the adjusting screw and original cover with the exclusion screw.

This device screws fully into the body of the regulator until it stops and puts the regulator out of action.The step opening feature of the main valve will still operate.

To Convert Nova Valve from L.P.G. to Natural Gas

1. Remove the cover of the pressure regulator.

2. Completely unscrew the exclusion screw and remove it.

3. Replace the exclusion screw with the regulator adjusting screw complete with its spring. Adjust for appropriate burner pressure. See Page 9, Section 4.4.

SECTION 15: TROUBLESHOOTING

53

SECTION 15: TROUBLESHOOTING15.1 General for Automatic Ignition

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For your safety and optimum heater performance use only ROBERTS GORDON® replacement parts.Conduct Commissioning procedure as on Page 38, Section 11


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15.1.1 General - Manual Ignition

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15.2 Troubleshooting For Automatic Ignition Burner Systems

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There are two possible burner controls used. Satronic DKG972 or Honeywell S4563. They both have similar operating sequences. Honewell has a built in ignition device.To measure flame current, connect a 0 - 50 µA DC meter in series with the flame probe by using the flame probe jack plug or connection at control box for Honeywell control.If the meter reads Negative values, then reverse the test leads. See Page 56, Section 15.2.1 for DKG 972 Control Box Data.



56

15.2.1 Satronic DKG 972 Control Information SystemThe Satronic DKG 972 control is a micro-processor control which provides information about the current operation of the burner and the cause of any faults.The information is available by reading the “flash code” at the red LED within the lockout reset button as detailed below.

FLASH CODE KEY❘ = short pulse❚ = long pulse. = short pause_ = long pause

15.2.2 Program Sequence DisplayMessages for normal operation

These indications will repeat as long as the lockout reset button is not reset.

15.2.3 Fault Display MessagesOn burner failure the red LED is illuminated for a period of approximately 10 seconds, followed by a brief “dark phase”, then one of the following flash codes will indicate the cause of the fault.This indication will repeat as long as the lockout reset button is not reset.

Lockout within lockout safety time.No flame establishment. ❘ ❚ ❚ ❚ ❚

Lockout during normal burner operationGas supply or detector failure. ❘ ❘ ❚ ❚ ❚

Lockout caused by manuallypressing the reset button. ❘ ❘ ❚ ❚ ❚ _ ❚ ❚ ❚ ❚ ❚

15.2.4 Additional Monitoring EquipmentBy the use of additional monitoring equipment, a short history of recorded faults is also available.There are two types of additional monitoring devices available from Satronic Ltd.The “satropen” is a small pocket reader designed to give a visual read out of status, flame current and supply voltage.Computer software is available to allow access to the current information, fault information and stored data.

Figure 26: Automatic Burner Control Box Sequence

MESSAGE FLASH CODE

Waiting time (tw) ❘ ❘ ❘ .

Pre-ignition (tvz) ❘ ❘ ❘ ❘ .

Safety time (ts) & post ignition (tn) ❚ ❘ .

Delay 2nd stage (tv2) ❚ ❘ ❘ .

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15.3 Flame Supervision System

15.3.1 Automatic Ignition Systems

15.3.2 Flame Supervision Systems - Manual Ignition

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15.4 Troubleshooting for Solenoid Valves

15.5 Troubleshooting for Main Fan

For “B” and “C” versions with two or more fans, a contactor will be used to operate fans. See Page 59, Section 15.6 for contactor troubleshooting.

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15.6 Troubleshooting for Fan Contactor

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SECTION 16: REMOVAL AND REPLACEMENT PARTSSee warnings and notes on Page 48, Section 13 before removing or replacing parts.

16.1 Burner Tray

16.1.1 Lower panels

Step 16.1.2 Gas Valve

Step 16.1.3 Remove Burner Tray16.2 Main Burner Bars / Injectors16.2.1 Burner Bar Removal

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the burner tray and valves separately.

NOTE: Burner tray has sharp edges. To avoid injury, use care when handling these components.

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16.2.2 Individual Bar and Injector Removal

16.2.3 Direct Main Flame Ignition for Automatic Ignition Up To Model 300.

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Description Part NumberMain Burner Injector - Natural Gas B094Main Burner Injector - LPG B095Sealing Washer B210

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16.3 Pilot Burner Assembly (where fitted).

CAUTION: Do not kink or tightly bend the pilot gas pipe or thermocouple.

Natural gas and L.P.G. operate utilizing different pilot injectors. See Page 50, Figure 23.

The difference between manual and automatic ignition is:

• Manual Ignition heaters are controlled with athermocouple.

• Automatic ignition are controlled with a flameprobe.

The ignition electrode has a small tag connector for connecting the HT lead and ALWAYS fits into the centre hole of the pilot burner bracket.The thermocouple or (flame probe with permanently connected P.T.F.E. insulated wire) is fitted in the end hole of the pilot burner bracket.

16.3.1 Removal of Pilot BurnerRemove the rear lower panel of the heater and disconnect the pilot burner connections. See Page 60, Section 16.1.

Step 16.3.2 Pilot Bracket Assembly

Step 16.3.3

Step 16.3.4

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Description Part NumberPilot Burner Bracket B186Spark Electrode J021Automatic Ignition Flame Probe J035Manual Ignition Thermocouple L432Pilot injector Nat gas (marked 34) B184Pilot injector LPG Gas (marked 19) B088


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16.4 Gas Control Valves16.4.1 General The gas control valves are easily accessible from the rear of the heater or may be withdrawn as part of the burner assembly.Remove the valves keeping the burner tray in place. The tables on Page 8, Section 4.3 through Page 10, Section 4.5 give details of the gas valve specified for use on the various heater models.

IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVES SPECIFIED FOR EACH MODEL TYPE ARE USED WHEN REPLACING THESE CONTROLS.

16.4.2 Removal of Gas Valves - All ModelsSee Page 60, Section 16.1.2 for gas valve removal.The pilot gas valves (where fitted) are supported on the inlet pipe fittings and the outlet is a 4 mm OD compression fitting. Electrical connection is by a three pin plug.To remove gas valves

1. Turn off gas and electrical supply.

2. Where fitted, disconnect the pilot gas pipe at the compression fitting at the pilot gas valve and thermocouple at valve.

3. Disconnect the union between the gas supply pipe and the gas valve.

4. Disconnect the electrical plugs to all gas valves.

5. Disconnect the union or valve outlet flange between the gas valve and the burner.

Disassemble gas train for automatic ignition1. Where a separate pilot is fitted, separate the

start and main gas valves.

2. Hold the main gas valve firmly in a vice and unscrew the pilot line from the main gas line at the ¼" elbow by ¼ turn.

3. Unscrew the pilot or the main gas valve from the main gas pipe.

To refit reverse the previous procedure.• Use only a minimum amount of non hardening

gas seal so that excess sealant is not carried into the valve mechanisms.

• Ensure valves are assembled with the marked gas flow in the correct direction.

• Ensure "O" ring seals are fitted to the inlet and outlet flanges where appropriate.

• Commission valve as on Page 39, Section 11.4.

• See Page 50, Section 14 for converting between natural gas and L.P.G.

16.4.3 ThermocoupleBe careful not to kink or crack the thermocouple tube.

Connect to the valve using the nut, screwed hand tight plus no more than ¼ turn with a spanner This is an electrical connection and must be clean, use NO compounds. See Page 62, Step 16.3.2 through Step 16.3.3.

16.4.4 Thermocouple Interrupter RelayAll manual ignition heaters are fitted with a thermocouple interrupter relay to interface between the limit thermostats and the thermocouple.

After replacement of limit thermostats or interrupter relay, perform commissioning checks to insure safe operation. See Page 38, Section 11.

Use only ROBERTS GORDON® replacement parts.

16.5 CUHA Axial Fan/Guard/Motor AssemblyThe Axial fan unit for the CUHA range of heaters is supplied completely assembled and balanced. These components are not replaceable separately.

Step 16.5.1 Fan Removal and Replacement

16.5.2 To Replace the Fan AssemblyTo replace the fan assembly reverse the procedure shown above. Fit rubber washers to the guard mountings to reduce vibration.

• Check that the fan blades are free to rotate before turning on the power to the fan.

• Strictly comply with the colour code of the fan wires to ensure correct operation. See Page 21, Section 10 wiring diagrams

• Replace the fan capacitor when changing a fan.

• Use only genuine ROBERTS GORDON®

replacement parts.

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Description Part NumberAxial Fan 35041-101 A262AAxial Fan 39041-101 A263AAxial Fan 42041-101 A264A


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16.6 CUHB & CUHC Centrifugal Fan/Guard/Motor AssemblyThe direct drive fan/s for the CUHB & CUHC range is supplied as a complete assembly. Take careful note of the electrical connections of the fan before disconnecting from the terminals.

For the CUHC versions fitted with an inlet spigot assembly, the fans may be accessed through the removable covers on the sides, top and bottom of the spigot, as required.

16.6.1 Fan Removal and Replacement

Remove the fan by removing the fixing screws while supporting the weight of the fan (approx. 19 kg).

16.6.2 To Replace the Fan(s)To reassemble reverse the procedure shown above.

• Fit new rubber seal between the fan flange and the heater rear panel.

• Fit to the rear panel in the correct orientation with the curved surface upwards.

• Strictly comply with the colour code of the fan wires to ensure correct operation. See Page 21, Section 10 Wiring diagrams.

• Use only genuine ROBERTS GORDON®

replacement parts. The three speed winding connections are:Low speed: White N, Red Live The other two windings are "parked" separately in spare terminals.Medium speed: White N, Blue live. The other two windings are "parked" separately in spare terminals.High speed: White N, Black live. The other two windings are "parked" separately in spare terminals.

• Check that the fan blades are free to rotate without catching before turning on the power to the fan.

16.7 Combination Fan/Limit Thermostat16.7.1 Removal and Replacement

1. Remove the cover retaining screw and pull off the cover.

2. Disconnect the electrical connections by push-ing in with a small screwdriver and pulling out the wires. See Page 12, Figure 5. The earth wire is held under a screw connection.

3. Unscrew two screws and withdraw the unit from the cabinet feeding the cables through the plas-tic conduit connection.

4. To refit, reverse the above procedure re-using the plastic conduit connection and reset as in the commissioning instructions on Page 38, Section 11 through Page 43, Section 11.12.

5. Remove link. See Page 12, Figure 5. Permanent damage and a fire hazard will be caused by leaving this link in.

6. Seal limit setting by a suitable method (paint spot) to prevent unauthorized adjustment.

16.8 Second Limit Thermostat16.8.1 Removal and Replacement

1. Remove the mounting nut securing the thermo-stat to the heater side.

2. Remove the heater lower rear panel to gain access to the body of the thermostat and its electrical connections.

3. Disconnect the push-on electrical connections from the thermostat.

NOTE: On Models 340 and 380 B & C versions the secondary limit thermostats are mounted on the fan mounting panel. The relevant fan will need to be removed to gain access to these thermostats.

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Description Part NumberTorin Fan DDC 270-270 A047Torin Fan DDC 241-241 A049

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4. Remove the fan assembly from the heater rear. See Page 63, Section 16.5.1 or See Page 64, Section 16.6

5. Carefully pull the capillary sensing probe through its access hole in the side of the heater heat exchanger being careful not to damage the capillary tube.

6. To refit a thermostat, first carefully straighten the capillary tube, it is important not to kink or crack it. Replace by reversing the above proce-dure

• Ensure that the sensing bulb is positioned against the base of the heat exchanger near the centre of the fan outlet. (Where there are two or three fans, the position of the sensing bulb should be towards the centre of the fan/s on the opposite side of the heater from the controls).

• Secure the capillary tube re-using the metal bracket.


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16.9 Major Components Descriptions

Axial Fan 35041-101 P/N A262ACUHA 60/100/200/240

Axial Fan 39041-101 P/N A263ACUHA 120/140

Axial Fan 42041-101 P/N A264ACUHA 160/180/280/300/340/380

Centrifugal Fan DDC 270-270 P/N A047CUHB/C 60/160/240/380

Centrifugal Fan DDC 241-241 P/N A049CUHB/C 180/200

Honeywell VR 420AB 1002 Main Gas Valve P/N L059B

S.I.T. Tandem (Natural Gas) 0.830.033 P/N L411Automatic Ignition Gas Valve

S.I.T. Tandem (L.P.G. Gas) 0.830.020 P/N L413Automatic Ignition Gas Valve

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S.I.T. Nova (All Gasses) 0.822.117.Automatic Ignition Gas Valve P/N L421

S.I.T. Nova (All Gasses) 0.820.054.Manual Ignition Gas Valve P/N L431


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Major Components Descriptions

S.I.T. Nova Exclusion Screw for L.P.G.0.907.037 P/N L425

Pilot Burner Injector - Marked 34. P/N B184(Natural Gas)

Pilot Burner Injector - Marked 19. P/N B088(L.P.G. Gas)

Pilot Burner Bracket P/N B186(all models)

Sealing Washer P/N B210for Main Burner Injector

Main Burner Injector - Marked 840. P/N B094(Natural Gas)Main Burner Injector - Marked 250. P/N B095(L.P.G. Gas)

Spark Igniter P/N J038for Direct Main Flame Ignition

Flame Probe P/N J039for Direct Main Flame Ignition

Spark Electrode P/N J021(all models with pilot burner)

Automatic Ignition Flame Probe P/N J035

S.I.T. 600mm Thermocouple P/N L432

Honeywell Combination P/N K017AFan/Limit Thermostat

Second Limit Thermostat P/N K120A

Thermocouple Interrupter Relay P/N L434

ˆ ˝ ˙ ˜ unit heaters $ # ˙ ˚˚ 2 installation,...

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