Roberts Gorden CTCU 11, CTCU 7, CTCU 22, CTCU 32, CTCU 27 User Manual
...
WARNING
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. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier’s
instructions.
8. If you cannot reach your gas
supplier, call the Fire Department.
Fire Hazard
Keep all flammable objects, liquids and
vapours the minimum required
clearances to combustibles away from
heater.
Some objects will catch fire or explode
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
damage.
WARNING
Installation must be done by a registered installer/
contractor qualified in the installation and service
of gas-fired heating equipment or your gas supplier.
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.
®
Combat
Compact Tubular Unit Heaters
Installation, Commissioning,
Operation & Service Manual
Models CTCU 7
CTCU 11
CTCU 15
CTCU 22
CTCU 27
CTCU 32
© 2012 Roberts-Gordon Europe Limited
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.
Roberts-Gordon Europe Limited
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands WS10 7SH UK
Telephone: +44(0)121 506 7700
Fax: +44 (0)121 506 7701
Service Telephone: +44 (0)121 506 7709
Service Fax: +44 (0)121 506 7702
E-mail: uksales@rg-inc.com
E-mail: export@rg-inc.com
www.rg-inc.com
www.combat.co.uk
P/ N 1111 0 0 U K R ev F 03/12
© 2011
Roberts-Gordon Europe Ltd
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 Europe Ltd.
TABLE OF CONTENTS
SECTION 1: Heater Safety...................................................... 2
1.1 Manpower Requirements .............................................2
1.2 Safety Labels and Their Placement ............................. 2
SECTION 2: Installer Responsibility .....................................4
2.1 Clearances to Combustibles ........................................ 4
2.2 Corrosive Chemicals.................................................... 4
2.3 National Standards and Applicable Codes .................. 4
SECTION 3: Clearances to Combustibles.............................5
3.1 Required Clearances to Combustibles.........................5
SECTION 4: Critcal Considerations ......................................7
4.1 Ventilation .................................................................... 7
4.2 Gas Supply .................................................................. 7
4.3 Electrical Supply .......................................................... 7
4.4 Flue..............................................................................7
SECTION 5: Specifications ....................................................8
5.1 CTCUA (All Models) ....................................................8
5.2 General Technical Data Table (All Models)..................9
5.3 Technical Data Table (All Models)................................ 9
SECTION 6: Heater Installation............................................ 10
6.1 General...................................................................... 10
6.2 Basic Information....................................................... 10
6.3 Location and Suspension .......................................... 10
6.4 Handling .................................................................... 10
6.5 Suspension and Shelf Mounting ................................ 10
6.6 Wall Mounting............................................................ 10
SECTION 7: Flue Installation ...............................................13
7. 1 F l ue Installation .......................................................... 13
7.2 Changing Flue and Air Intake Orientation ..................13
7.3 Type C
7.4 Type B
SECTION 8: Air Supply......................................................... 16
8.1 Room Sealed Installation........................................... 16
8.2 Open Flued Installation.............................................. 16
8.3 Building Ventilation .................................................... 16
SECTION 9: Gas Pipe Work.................................................. 17
9.1 Connections............................................................... 17
SECTION 10: Wiring and Electrical Information................. 19
10.1 Electrical Supply ...................................................... 19
10.2 Remote Controls ...................................................... 19
10.3 CTCUA Wiring Diagram (Models 7-32) .................... 20
SECTION 11: Commissioning ..............................................21
11.1 Pre-Commission Checks .......................................... 21
11.2 Gas Supply ...............................................................21
11.3 Mechanical Checks................................................... 21
11.4 Begin Commissioning ...............................................22
11.5 Combustion Testing ..................................................23
11.6 Turning Off the Heater .............................................. 23
11.7 External Controls ...................................................... 23
11.8 Complete the Commissioning...................................24
11.9 Instruction to the User .............................................. 24
SECTION 12: User Instructions ...........................................25
12.1 User Instructions...................................................... 25
12.2 Heater Operation .....................................................25
12.3 Common User Controls ........................................... 25
12.4 Lighting Instructions.................................................26
12.5 Simple Fault Finding ................................................ 26
, C32 & C62 Appliance..................................... 13
12
Appliance ..................................................... 13
22
SECTION 13: Servicing.........................................................27
13.1 Servicing Instructions...............................................27
13.2 Burner Maintenance.................................................27
13.3 Fan/Motor Assembly Maintenance...........................27
13.4 Heat Exchanger Maintenance..................................27
13.5 Gas Control Valve Maintenance...............................28
13.6 Flue Fan ...................................................................28
13.7 Maintenance Checklist .............................................28
SECTION 14: Conversion Between Gases ..........................30
14.1 General ....................................................................30
14.2 Burner Conversion ...................................................30
14.3 Gas Valves...............................................................30
SECTION 15: Troubleshooting .............................................31
15.1 General ....................................................................32
15.2 Troubleshooting For Automatic Ignition Burner
Systems....................................................................33
15.3 Troubleshooting for Flame S
15.4 Troubleshooting for Solenoid Valves ........................34
15.5 Troubleshooting for Main Fan...................................35
SECTION 16: Removal and Replacement Parts..................36
16.1 Gas Valve.................................................................36
16.2 Burner Compartment ...............................................37
16.3 Ignition Electrode and Flame Probe.........................38
16.4 Flue Fan Vertical Installation (Models 7 - 15)...........39
16.5 Flue Fan Vertical Installation (Models 22 - 32).........40
16.6 Pressure Switch........................................................41
16.7 Ignition Control .........................................................42
16.8 CTCUA Axial Fan/Guard/Motor Assembly ...............42
16.9 Fan and Limit Thermostats ......................................42
upervision System .......34
Printed in U.K.
TABLE OF FIGURES
Figure 1: Front and Back Panel Label Placement ..................... 2
Figure 2: Side Panel Label Placement......................................3
Figure 3: Installation Clearances and Clearances to
Combustibles............................................................. 6
Figure 4: Suspension Methods ............................................... 11
Figure 5: Shelf Mounting and Hanging Suspension................12
Figure 6: Vertical Louvres (Optional) ...................................... 12
Figure 7: Flue and Roof Detail ................................................ 14
Figure 8: Vertical and Horizontal Flue Termination -
Type B
Figure 9: Vertical and Horizontal Flue Termination -
Type C
Figure 10: Gas Connection with Stainless Steel Flex
Figure 11: Automatic Burner Control Box Sequence............... 22
Figure 12: Gas Valve for Heater (Models 7 - 32)..................... 23
Figure 13: Heater Operating Sequence .................................. 25
Appliance .................................................. 14
22
& C62 Appliances.................................15
12 C32
Connector .............................................................. 18
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.
®
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
1 of 42
COMBAT® CTCU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
Description Part Number
Logo Label 91040030
Address Label 91040006
Lockout Reset Label 91038303
Rating Plate Label 91040001
Connection Diagram Label 91040022
SECTION 1: HEATER SAFETY
Yo ur 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.
Before installation, check that the local distribution
conditions, nature of gas and pressure, and
adjustment of the appliance are compatible.
The heater must be applied and operated under the
general concepts of reasonable use.
This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given
supervision or instruction concerning use of the
appliance by a person responsible for their safety.
Children should be supervised to ensure that they
do no play with the appliance.
This heater is designed for heating non-residential
indoor spaces. Do not install in residential spaces.
These instructions, the layout drawing, local codes
For additional copies of the Installation, Operation
and Service Manual, please contact Roberts-
Gordon Europe Limited.
and ordinances, and applicable standards that apply
to gas piping, electrical wiring, venting, etc. must be
thoroughly understood before proceeding with the
installation.
1.1 Manpower Requirements
To p re vent personal injury and damage to the
heater, two persons will be required for installation
Protective gear is to be worn during installation,
operation and service. Thin sheet metal parts have
sharp edges. To prevent injury, the use of work
ves is recommended. The use of gloves will also
glo
prevent the transfer of body oils from the hands.
.
1.2 Safety Labels and Their Placement
Product safety signs or labels sho
the product user when they are no longer legible.
Contact Roberts-Gordon for obtaining replacement
signs or labels. See Page 2, Figure 1 through Page
3, Figure 2.
Figure 1: Front and Back Panel Label Placement
uld be replaced by
2 of 42
Figure 2: Side Panel Label Placement
Description Part Number
Lighting Label 91040002
Wiring Diagram Label 91040020
SECTION 1: HEATER SAFETY
3 of 42
COMBAT® CTCU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
CAUTION
Product Damage Hazard
Do not use heater in area containing
corrosive chemicals.
Refer to appropriate Material Safety Data
Sheets (MSDS).
Failure to follow these instructions can result
in product damage.
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
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.
• To safely and adequately install heater using
materials with a minimal working load of 33 kg.
• To ensure the heater is placed in an approved
application.
2.1 Clearances to Combustibles
A laminated wall tag is available for the heater as a
permanent reminder of the safety instructions and
the importance of the required clearances to
combustibles. Affix the tag by peeling off the backing
of the adhesive strips on the rear surface and
position the tag on a wall near the heater (e.g.
®
thermostat or ROBERTS GORDON
Controller).
A copy of the wall tag (P/N 91040029) is illustrated
on the back cover. Know your model number and
installed configuration. Model number and installed
configuration are found on the burner and in the
Installation, Operation and Service Manual. Write
the largest clearance dimensions with permanent
ink according to your model number and
configuration in the open spaces on the tag.
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 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.
4 of 42
SECTION 3: CLEARANCES TO COMBUSTIBLES
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapours the minimum required clearances to
combustibles away from heater.
Some objects will catch fire or explode when
placed close to heater.
Failure to follow these instructions can result
in death, injury or property damage.
SECTION 3: CLEARANCES TO COMBUSTIBLES
3.1 Required Clearances to Combustibles
Clearances are the required distances that
combustible objects must be away from the heater
to prevent fire hazards. Caution should be used
when running the system near combustibles.
Combustibles are materials, which may catch on fire
and include common items such as wood, paper,
rubber, fabric, etc. Maintain clearances to
combustibles at all times for safety.
Clearances around the heater and flue must be as
indicated on Page 6, Figure 3, to ensure access for
servicing, and correct operation. If clearances to
combustibles are not indicated, then installation
clearances apply.
Check the clearances on each burner for the model
heater being installed to make sure the product is
suitable for your application and the clearances are
maintained. Read and follow the safety guidelines
below:
• Keep petrol or other combustible materials
including flammable objects, liquids, dust or
vapours a
ance.
• The stated clearances to combustibles represents a surface temperature of 32°C (90° F)
above room temperature. Building materials with
a low heat tolerance (such as plastics, vinyl sid-
ing, canvas, tri-ply, etc) may be subject to degradation at lower temperatures. It is the installer’s
responsibility to assure that adjacent materials
are protected from degradation.
• Maintain clearances from heat sensitive equip-
ment and workstations.
• Maintain clearances from vehicles parked below
the heater.
• Maintain clearances from swinging and over-
head doors, overhead cranes, vehicle lifts, parti-
way from this heater or any other appli-
tions, storage racks, hoists, building
construction, etc.
• In locations used for the storage of combustible
materials, signs must be posted to specify the
maximum permissible stacking height to maintain required clearances from the heater to the
combustibles. Signs must be posted adjacent to
the heater thermostat. In the absence of a thermostat, signs must be posted in a conspicuous
location.
• Consu
Carrier or other authorities for approval of pro-
posed installation when there is a possibility of
exposure to combustible airborne materials or
vapours.
• Hang heater in accordance to the minimum
suspension requirements on Page 10, Section 6
and Page 11, Figure 4 through Page 12, Figure
5.
• Affix the tag on a wall near the heater.
lt local Building Inspector, Fire Insurance
5 of 42
COMBAT® CTCU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
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.
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.
* Heaters may be mounted at a higher level if destratification
fans are installed.
**80 cm is necessary to service
heater.
Figure 3: Installation Clearances and Clearances to Combustibles
6 of 42
SECTION 4: CRITCAL CONSIDERATIONS
WARNING
Carbon Monoxide Hazard
Heaters may be installed vented or unvented.
Vented heaters must be vented outdoors.
Unvented heaters must be installed in
buildings with ventilation rates as per
section 7.
Failure to follow these instructions can result
in death or injury.
4.1 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.
4.2 Gas Supply
SECTION 4: CRITCAL CONSIDERATIONS
4.3 Electrical Supply
DANGER
Electrical Shock Hazard
Disconnect electric before service.
Heater must be properly grounded.
Failure to follow these instructions can result
in death or electrical shock.
A permanent 230 V 50 Hz 1Ø electrical supply is
required at the main electrical terminals. The heater
also requires suitable energy controls in accordance
with Section 10.
4.4 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 13, Section 7).
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.
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.
7 of 42
COMBAT® CTCU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
Rear View
Top View
Air Intake
on Model 22
728
A
Gas Supply
B
171
Lockout Reset
Electrical
Connection
Flue
Air Intake
45
85
D
448
120
End View
660
514
Mounting
Holes
422
Mounting
Holes
448 26514
C
171
120
Air Intake
(Optional Position)
Flue
(Optional Position)
4 x M10 Captive Nuts Provided
463
4 x M10 Captive Nuts Provided
*
* 140 for 27 - 32
SECTION 5: SPECIFICATIONS
5.1 CTCUA (All Models)
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)
(12.0)
(9.4)
(5.9)
(2.7)
304
239
151
68
304
(12.0)
239
(9.4)
151
(5.9)
68
(2.7)
450
(17.7)
385
(15.2)
151
(5.9)
68
(2.7)
450
(17.7)
385
(15.2)
172
(6.8)
46
(1.8)
578
(22.8)
513
(20.2)
149
(5.9)
59
(2.3)
8 of 42
SECTION 5: SPECIFICATIONS
5.2 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
Run Cur r e n 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
/h 1120 1220 2710 2750 4474
Air Throw m 9 12 14 16 16
Sound Pressure Level at 3 m
[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.
5.3 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 9.59.59.59.59.09.0
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 9.09.09.59.29.29.3
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
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
Gas Rate
CTCUA R - 1/2" R - 1/2" R - 1/2" R - 1/2" R - 1/2" R - 1/2"
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
/h
m
3
ft
/h
3
/h
m
3
ft
/h
3
/h
m
kg/h
3
/h
m
kg/h
8.5
29
7. 7
26
7. 1
24
0.8
29
0.9
33
0.3
0.59
0.2
0.6
13.4
46
12.1
41
11.1
38
1. 3
45
1. 5
52
0.5
0.93
0.4
0.94
18.3
6227.5 9433
16.5
24.8
56
15.1
52
1. 7
2.6
62
2.0
72
108
0.7
1. 2 7
0.5
1. 2 8
1. 9 1
0.8
1. 9 3
85
23
78
93
3
1
Gas Connection
Gas rates corrected to standard conditions 1013.25 mbar 15° C
113
29.7
101
27.2
93
3.1
110
3.6
127
1. 2
2.3
.9
2.31
38.5
131
34.7
118
31.7
108
3.6
127
4.2
148
1. 4
2.68
1. 1
2.7
9 of 42
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