Roberts Gorden CTCU, CTCU 11, CTCU 15, CTCU 27, CTCU 22 User Manual
...
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Leave the building.
6. Immediately call your local gas
supplier after leaving the building.
Follow the gas suppliers
instructions.
7. If you cannot reach your gas
supplier, call the Fire Department.
WARNING
®
C mbat
Compact Tubular Unit Heaters
Installation, Commissioning,
Operation & Service Manual
Models CTCU 7
CTCU 11
CTCU 15
CTCU 22
Fire Hazard
Do not store or use petrol or other
flammable vapours and liquids in the
vicinity of this or any other appliance.
Some objects will catch fire or explode
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
damage.
WARNING
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.
Installation must be done by a registered installer/
contractor qualified in the installation and service
of gas-fired heating equipment or your gas supplier.
CTCU 27
CTCU 32
Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Owner
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Quality in Any Language™
© Copyright 2006 Roberts-Gordon, LLC
Roberts-Gordon Europe Limited
Oxford Street
Bilston, West Midlands WV14 7EG UK
Telephone: +44(0) 1902 494425
Fax: +44(0) 1902 403200
Service Telephone: +44(0) 1902 498733
Service Fax: +44(0) 1902 401464
E-mail: uksales@rg-inc.com
E-mail: export@rg-inc.com
www.rg-inc.com
P/N 11110 0 UK Re v B 10 / 0 6
TABLE OF CONTENTS
SECTION 1: Heater Safety...................................................... 2
SECTION 2: Installer Responsibility .....................................2
2.1 Clearances to Combustibles ........................................ 2
2.2 Corrosive Chemicals....................................................2
2.3 National Standards and Applicable Codes .................. 2
SECTION 3: Critical Considerations .....................................3
3.1 Basic Information......................................................... 3
3.2 Location and Suspension ............................................3
3.3 Minimum Required Installation Clearances .................3
3.4 Clearances to Combustibles ........................................ 3
3.5 Ventilation .................................................................... 3
3.6 Gas Supply ..................................................................3
3.7 Electrical Supply .......................................................... 3
3.8 Flue..............................................................................3
SECTION 4: Specifications ....................................................5
4.1 CTCUA (All Models) ....................................................5
4.2 General Technical Data Table (All Models) ..................6
4.3 Technical Data Table (All Models)................................6
SECTION 5: Heater Installation.............................................. 7
5.1 General........................................................................ 7
5.2 Shelf Mounting and Suspension.................................. 7
5.3 Wall Mounting.............................................................. 7
SECTION 6: Flue Installation .................................................9
6.1 Changing Flue and Air Intake Orientation.................... 9
6.2 Flue Installation............................................................9
6.3 Type C
6.4 Type B
SECTION 7: Air Supply......................................................... 11
7.1 Room Sealed Installation ........................................... 11
7.2 Open Flued Installation .............................................. 11
7.3 Building Ventilation ..................................................... 11
SECTION 8: Gas Piping........................................................12
8.1 Connections............................................................... 12
SECTION 9: Wiring and Electrical Information................... 13
9.1 Electrical Supply ........................................................ 13
9.2 Remote Controls ........................................................ 13
9.3 CTCUA Wiring Diagram Models 7 - 32...................... 14
SECTION 10: Commissioning..............................................15
10.1 Pre-Commission Checks.......................................... 15
10.2 Begin Commissioning ..............................................15
10.3 Complete the Commissioning ..................................17
SECTION 11: User Instructions............................................ 18
11.1 User Instructions.......................................................18
11.2 Heater Operation ...................................................... 18
11.3 Common User Controls ............................................ 18
11.4 Lighting Instructions..................................................18
11.5 Simple Fault Finding................................................. 19
SECTION 12: Servicing.........................................................20
12.1 Servicing Instructions .............................................. 20
12.2 Burner Maintenance ................................................20
12.3 Fan/Motor Assembly Maintenance........................... 20
12.4 Heat Exchanger Maintenance..................................20
12.5 Gas Control Valve Maintenance...............................20
12.6 Flue Fan................................................................... 20
, C32 & C62 Appliance ...................................... 9
12
Appliance....................................................... 9
22
SECTION 13: Conversion Between Gases ..........................21
13.1 General ....................................................................21
13.2 Burner Conversion ...................................................21
13.3 Gas Valves ...............................................................21
SECTION 14: Troubleshooting .............................................22
14.1 General ....................................................................22
14.2 Troubleshooting For Automatic Ignition
Burner Systems .......................................................23
14.3 Troubleshooting for Flame Supervision System .......24
14.4 Troubleshooting for Solenoid Valves ........................25
14.5 Troubleshooting for Main Fan...................................25
SECTION 15: Removal and Replacement Parts..................26
15.1 Gas Valve .................................................................26
15.2 Burner Compartment ...............................................27
15.3 Ignition Electrode and Flame Probe.........................28
15.4 Flue Fan Vertical Installation ....................................29
15.5 Pressure Switch........................................................30
15.6 Ignition Control .........................................................31
15.7 CTCUA Axial Fan/Guard/Motor Assembly ...............31
15.8 Fan and Limit Thermostats ......................................31
© 2006
Roberts-Gordon, LLC
All rights reserved. No part of this work covered by the copyrights herein may be reproduced
or copied in any form or by any means - graphic, electronic, or mechanical, including
photocopying, recording, taping or information storage and retrieval systems - without the
written permission of Roberts-Gordon, LLC.
Printed in U.S.A.
TABLE OF FIGURES
Figure 1: Installation Clearances and Clearances to
Combustibles.............................................................. 4
Figure 2: Suspension Methods ................................................. 7
Figure 3: Shelf Mounting and Hanging Suspension.................. 8
Figure 4: Vertical Louvres (Optional) ........................................8
Figure 5: Flue and Roof Detail ..................................................9
Figure 6: Vertical and Horizontal Flue Termination -
Type B
Figure 7: Vertical and Horizontal Flue Termination -
Type C
Figure 8: Gas Connection with Stainless Steel
Flex Connector......................................................... 12
Figure 9: Automatic Burner Control Box Sequence ................16
Figure 10: Gas Valve for Heater Models 7 - 32 ....................... 16
Figure 11: Heater Operating Sequence...................................18
Appliance ................................................... 10
22
& C62 Appliances.................................. 10
12 C32
®
COMBAT
Compact Tubular Unit Heaters are high efficiency heaters and are listed on
the Enhanced Capital Allowance Scheme ’Energy Technology Product List’. The ETL
symbol is a UK registered certification mark of The Carbon Trust.
Product Approval
ROBERTS GORDON® appliances have been tested and CE certified as complying with the essential
requirements of the Gas Appliance Directive, the Low Voltage Directive, the Electromagnetic
Compatibility Directive and the Machinery Directive for use on natural gas and LPG when installed,
commissioned and maintained in accordance with these instructions.
These instructions refer to appliances designed to operate in the European Union.
Appliances designed for other countries (non European Union) are available on request.
This appliance must be installed in accordance with the local and national codes in force and used
only in a sufficiently ventilated space, as specified in these instructions.
Before installation, check that the local gas distribution systems, nature of gas and pressure, and
adjustment of the appliance are compatible.
1
COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 1: HEATER SAFETY
Your Safety is Important to Us!
This symbol is used throughout the
clearances to combustibles. Affix the tag on a wall
near the heater.
manual to notify you of possible fire,
electrical or burn hazards. Please pay
2.2 Corrosive Chemicals
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
Do not use heater in an area containing corrosive
chemicals.
qualified in the installation and service of gas-fired
heating equipment.
Read this manual carefully before installation,
operation, or service of this equipment.
Corrosive chemicals will damage the burner and
heat exchanger parts.
Failure to follow these instructions can result in
property damage.
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.
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
SECTION 2: INSTALLER RESPONSIBILITY
• 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, Fire Officer or insurance
company for guidance.
• To use the information given in the manual
together with the local and national codes 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, flues and air
premises.
* Halogenated Hydrocarbons are a family of chemical
compounds characterized by the presence of halogen
elements (fluorine, chlorine, bromine, etc.). These
compounds are frequently used in refrigerants, cleaning
agents, solvents, etc. If these compounds enter the air
supply of the burner, the lifespan of the heater
components will be greatly reduced. Warranty will be
invalid if the heater is exposed to halogenated
hydrocarbons.
2.3 National Standards and Applicable Codes
All appliances must be installed in accordance with
the latest revision of applicable standards and local
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.
intakes.
• To provide access to burners for servicing.
• 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 or
suspend anything from heater.
• To ensure that there is sufficient ventilation in the
area to comply with the requirements of
all relevant local and national codes.
2.1 Clearances to Combustibles
In all situations, clearances to combustibles must be
maintained. Caution must be used when running the
heater near combustible materials such as wood,
paper, rubber, etc. A wall tag is on the back cover of
this manual as a permanent reminder of the safety
instructions and the importance of the required
CAUTION
2
SECTION 3: CRITICAL CONSIDERATIONS
3.1 Basic Information
CTCU heaters have automatic ignition burners for
ON/OFF operation only.
3.2 Location and Suspension
All models:
• Must be installed indoors.
• Must be installed in a level position with horizontal or vertical discharge.
• May be mounted on a shelf of non-combustible
material. (See Page 5, Section 4 and Page 7,
Figure 2 for support points.)
• May be suspended from above (See Page 7, Fig-
ure 2) or from wall brackets of sufficient strength
to support the heater as listed in the Dimension
Data Table on Page 5, Section 4.1. Drop rods
must be a minimum of 10 mm diameter mild
steel. Four suspension points (M10 nuts) are
located on top and back side of the heater.
• Must be installed in a manner which allows
access to all serviceable components.
SECTION 3: CRITICAL CONSIDERATIONS
3.8 Flue
Choose heater siting to allow for the proper location
of the flue. Each heater must be fitted with an
individual and correctly sized sealed flue system
(See Page 9, Section 6).
No other appliance may be connected to the flue.
For room sealed installation, the air intake must be
the same size sealed system and the flue/air intake
must terminate at an approved concentric wall or
roof terminal.
3.3 Minimum Required Installation Clearances
Clearances around the heater and flue must be as
indicated on Page 4, Figure 1; Page 9, Figure 5
through Page 10, Figure 7 to ensure access for
servicing, and correct operation.
3.4 Clearances to Combustibles
Clearances must be as indicated on Page 4, Figure
1. If clearances to combustibles are not indicated,
then installation clearances apply.
3.5 Ventilation
It 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 and national codes.
3.6 Gas Supply
It is important that the gas supply pipe is sized
correctly to provide the inlet pressure as stated on
the heater data plate. The gas supply pipe and
electrical connections must not support any of the
heater's weight.
3.7 Electrical Supply
A permanent 230 V 50 Hz 1 Ø electrical supply is
required at the main electrical terminals. The heater
also requires suitable energy controls in accordance
with Section 9.
3
COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
WARNING
Fire Hazard
Some objects will catch fire or explode when placed
close to heater.
Keep all flammable objects, liquids and vapours the
required distance away from the heater.
Failure to follow these instructions can result in death,
injury or property damage.
Figure 1: Installation Clearances and Clearances to Combustibles
Installation Clearances
Roof Terminal
Air
Intake
Wall
Terminal
Flue
25 cm
15 cm
3 m
2.5 - 3.5 m*
Roof Terminal
3 m
* Heaters may be mounted at a higher level if destratification
fans are installed.
The heater must always be installed at least 1.8 m above the floor.
The flue pipe must have clearance from combustibles by 5 cm.
Clearances to Combustibles
15 cm
50 cm** 10 cm
30 cm
**80 cm is necessary to service
heater.
If installed at low levels where individuals can come in contact with hot heat exchanger components,
adequate guarding must be provided.
All distances are minimum clearance requirements for service access, air flow and safety.
4
SECTION 4: SPECIFICATIONS
4.1 CTCUA (All Models)
Top View
448 26514
422
Mounting
Holes
463
C
120
SECTION 4: SPECIFICATIONS
4 x M10 Captive Nuts Provided
Air Intake
(Optional Position)
Flue
(Optional Position)
171
Rear View
4 x M10 Captive Nuts Provided
448
B
Mounting
Holes
728
* 140 for 27 - 32
Dimension Data - CTCUA (All Models)
Model CTCU-7 CTCU-11 CTCU-15 CTCU-22 CTCU-27 / 32
Height
A
Mounting Hole Spacing
B
Centre of Flue (Top Option)
C
Centre of Flue
D
Weight kg 28 30.5 38.5 41 52.3
mm
(in)
mm
(in)
mm
(in)
mm
(in)
120
*
Air Intake
Electrical
Connection
Lockout Reset
Gas Supply
304
(12.0)
239
(9.4)
151
(5.9)
68
(2.7)
Flue
171
Air Intake
on Model 22
D
45
85
304
(12.0)
239
(9.4)
151
(5.9)
68
(2.7)
A
End View
450
(17.7)
385
(15.2)
151
(5.9)
68
(2.7)
514
450
(17.7)
385
(15.2)
172
(6.8)
46
(1.8)
660
578
(22.8)
513
(20.2)
149
(5.9)
59
(2.3)
5
COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
4.2 General Technical Data Table (All Models)
Model CTCU-7 CTCU-11 CTCU-15 CTCU-22 CTCU-27 / 32
CTCUA, Axial Fans
Total Electrical Load W 260 274 336 384 345
R u n C u r ren t A 1.1 1. 2 1. 5 1. 7 1. 5
Start Current A 1.7 1.8 2.5 2.9 2.6
3
Air Flow m
Sound Pressure Level at 3 m
/h 1120 1220 2710 2750 4474
[NR]
dB(A)
[31]
37
[35]
41
[39]
45
[42]
48
[42]
48
Flue and AIr Intake
Flue and Air Intake Size mm Ø 80 80 80 80 100
*Maximum Straight Flue/Air Intake m 2.5 4 5 5 5
Electrical load at 230 V 50 Hz measured by calculating from total run current of appliance.
* Do not exceed the maximum length of flue stated or heater may not operate properly.
Reduce the maximum length stated by 1 m for each 90° bend installed.
**If minimum air flow requirements are not met, then temperature limit devices will shut down the heater.
4.3 Technical Data Table (All Models)
Appliance Category II
Heat Input
Gross CV
Heat Input
Net CV
Approximate
Heat Output
Natural Gas (G20) Data - Inlet Pressure 20 mbar (7.8 in WG) Min. 17 mbar (6.8 in WG) Max. 25 mbar (10 in WG)
Burner Pressure mbar 9.5 9.5 9.5 9.5 9.0 9.0
Gas Rate
Natural Gas (G25) Data - Inlet Pressure 25 mbar (10 in WG) Min. 20 mbar (7.8 in WG) Max. 30 mbar (12 in WG)
Burner Pressure mbar 9.0 9.0 9.5 9.2 9.2 9.3
Gas Rate
LPG / Propane (G31) Data - Inlet Pressure 37 mbar (14.6 WG) Min. 25 mbar (10 in WG) Max. 45 mbar (18 in WG)
Alternative where permitted 50 mbar (20 in WG) Min. 42.5 bar (17 in WG) Max. 57.5 mbar (23 in WG)
Burner Pressure mbar 25.6 29.4 29.4 28.6 29.9 29.9
Gas Rate
2H/L 3B/P
Model CTCU-7 CTCU-11 CTCU-15 CTCU-22 CTCU-27 CTCU-32
kW
(Btu/h) x (1000)
kW
(Btu/h) x (1000)
kW
(Btu/h) x (1000)
3
m
/h
3
ft
/h
3
m
/h
3
ft
/h
3
/h
m
3
kg
/h
8.5
29
7. 7
26
7. 1
24
0.8
29
0.9
33
0.3
0.16
13.4
46
12.1
41
11.1
38
1. 3
45
1. 5
52
0.5
0.25
6227.5 9433
18.3
16.5
24.8
56
15.1
52
1. 7
62
2.0
72
0.7
0.34
0.51
85
23
78
2.6
93
3
108
1
113
29.7
101
27.2
93
3.1
110
3.6
127
1. 2
.61
38.5
131
34.7
118
31.7
108
3.6
127
4.2
148
1. 4
.71
LPG / Butane (G30) Data - Inlet Pressure 29 mbar (11,4 in WG) Min. 20 mbar (7.8 in WG) Max. 35 mbar (13.8 WG)
Burner Pressure mbar 19.2 21.9 22.9 21.4 21.4 22.4
3
/h
Gas Rate
m
kg
3
/h
0.2
0.09
0.4
0.14
0.5
0.19
0.8
0.29
Gas rates corrected to standard conditions 1013.25 mbar 15° C.
6
.9
.34
1. 1
.42
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