Page 1
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.
®
Combat
Tubular Unit Heaters
Installation, Commissioning,
WARNING
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.
Operation & Service Manual
Model CTU
22 to 115
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.
Quality in Any Language™
© Copyright 2007 Roberts-Gordon, LLC
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
P/N X407UK Rev G 10/07
Page 2
Page 3
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 CTUA ..........................................................................5
4.2 CTUB, CTUC and CTUD............................................. 6
4.3 General Technical Data Table ..................................... 7
4.4 Technical Data Table....................................................8
SECTION 5: Heater Installation.............................................. 9
5.1 General........................................................................9
5.2 Handling ......................................................................9
5.3 Shelf Mounting and Suspension..................................9
SECTION 6: Flue Installation ............................................... 10
6.1 Flue Installation.......................................................... 10
6.2 Type C12, C32 & C62 Appliance .................................... 10
6.3 Type B22 Appliance..................................................... 10
SECTION 7: Air Supply......................................................... 12
7.1 Room Sealed Installation ........................................... 12
7.2 Open Flued Installation .............................................. 12
7.3 Building Ventilation ..................................................... 12
7.4 Isolated Equipment Rooms ........................................ 12
SECTION 8: Optional Heater Configurations...................... 13
8.1 Distribution Duct Work for CTUB, CTUC and CTUD
Heaters ...................................................................... 13
SECTION 9: Gas Piping........................................................ 14
9.1 Connections............................................................... 14
SECTION 10: Wiring and Electrical Information................. 15
10.1 Electrical Supply ...................................................... 15
10.2 Remote Controls ...................................................... 15
10.3 CTUA Wiring Diagram (Models 22-60) .................... 16
10.4 CTUA Wiring Diagram (Models 75-115)................... 17
10.5 CTUB/C Wiring Diagram (Models 22-40)................. 18
10.6 CTUB/C Wiring Diagram (Models 50-60)................. 19
10.7 CTUB/C Wiring Diagram (Models 75-115) ............... 20
10.8 CTUD Wiring Diagram (Models 22-60) .................... 21
10.9 CTUD Wiring Diagram (Models 75-115)...................22
10.10 CTUD External Motor Alternative Wiring &
Optional Thermostat/Time Switch ..........................23
SECTION 11: Commissioning ..............................................24
11.1 Pre-Commission Checks .......................................... 24
11.2 Gas Supply...............................................................24
11.3 Mechanical Checks................................................... 24
11.4 Begin Commissioning ...............................................24
11.5 Combustion Testing ..................................................26
11.6 Turning Off the Heater ..............................................26
11.7 External Controls ......................................................27
11.8 Complete the Commissioning...................................27
11.9 Instruction to the User .............................................. 27
SECTION 12: User Instructions............................................28
12.1 User Instructions......................................................28
12.2 Heater Operation......................................................28
12.3 Common User Controls............................................28
12.4 Lighting Instructions.................................................28
12.5 Simple Fault Finding.................................................29
SECTION 13: Servicing.........................................................30
13.1 Servicing Instructions...............................................30
13.2 Burner Maintenance.................................................30
13.3 Fan/Motor Assembly Maintenance...........................30
13.4 Heat Exchanger Maintenance..................................30
13.5 Gas Control Valve Maintenance...............................30
13.6 Flue Fan ...................................................................30
SECTION 14: Conversion Between Gases ..........................31
14.1 General ....................................................................31
14.2 Burner Conversion ...................................................31
14.3 Gas Valves ...............................................................31
SECTION 15: Troubleshooting .............................................32
15.1 General ....................................................................32
15.2 Troubleshooting For Automatic Ignition Burner
Systems ...................................................................33
15.3 Troubleshooting for Flame Supervision System .......34
15.4 Troubleshooting for Solenoid Valves ........................34
SECTION 16: Removal and Replacement Parts..................35
16.1 Gas Valve.................................................................35
16.2 Burner Compartment ...............................................36
16.3 Ignition Electrode and Flame Probe.........................37
16.4 Flue Fan ...................................................................38
16.5 Pressure Switch........................................................39
16.6 Ignition Control .........................................................40
16.7 CTUA Axial Fan/Guard/Motor Assembly ..................40
16.8 CTUB & CTUC Centrifugal Fan/Guard/Motor
Assembly..................................................................40
16.9 Fan Data...................................................................41
© 2007
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.K.
Page 4
Page 5
TABLE OF FIGURES
Figure 1: Installation Clearances and Clearances to
Combustibles.............................................................4
Figure 2: Suspension Methods .................................................9
Figure 3: Flue and Roof Detail ................................................ 10
Figure 4: Air Intake Terminal Cover......................................... 10
Figure 5: Vertical and Horizontal Flue Termination -
Type B22 Appliance .................................................. 11
Figure 6: Vertical and Horizontal Flue Termination -
Type C12 C32 & C62 Appliances................................. 11
Figure 7: Heaters Installed in Isolated Equipment Rooms ...... 12
Figure 8: Ducting..................................................................... 13
Figure 9: Gas Connection with Stainless Steel Flex
Connector................................................................ 14
Figure 10: Automatic Burner Control Box Sequence...............25
Figure 11: Gas Valve for Heater (Models 22 - 60) ................... 25
Figure 12: Gas Valve for Heater (Models 75 - 115) .................26
Figure 13: Heater Operating Sequence ..................................28
Figure 14: Centrifugal Fan Orientation.................................... 41
Page 6
Page 7
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
Page 8
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 1: HEATER SAFETY
Your Safety is Important to Us!
2.2 Corrosive Chemicals
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.
Do not use heater in an area containing corrosive
chemicals.
Corrosive chemicals will damage the burner and
heat exchanger parts.
Failure to follow these instructions can result in
property damage.
Read this manual carefully before installation,
operation, or service of this equipment.
Roberts-Gordon cannot be responsible for ensuring
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.
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.
CAUTION
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.
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 (P/N 91040028) is on
the back cover of this manual as a permanent
reminder of the safety instructions and the
importance of the required clearances to
combustibles. Affix the tag on a wall near the heater.
* 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 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.
2
Page 9
SECTION 3: CRITICAL CONSIDERATIONS
3.1 Basic Information
CTU 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.
• May be mounted on a shelf of non-combustible
material. (
See Page 5, Section 4 and Page 9,
Figure 2 for support points)
• May be suspended from above (See Page 9,
Figure 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 of the heater.
• Must be installed in a manner which allows the
hinged door to be fully opened to provide 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 10, 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 10, Figure 3
through Page 11, Figure 6 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 electrical supply is
required at the main electrical terminals. The heater
also requires suitable energy controls in accordance
with
Section 10.
3
Page 10
COMBAT® CTU UNIT HEATERS 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
60 cm
15 cm
3 m
2.5 - 3.5 m*
* Heaters may be mounted at a higher level if
destratification fans and/or turn down nozzles are
installed.
Clearances to Combustibles
15 cm
50 cm 50 cm**
30 cm
**80 cm is necessary to service heater.
The heater must always be installed at least 2.5 m above the floor.
The flue pipe must have clearance from combustibles by 5 cm.
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
Page 11
SECTION 4: SPECIFICATIONS
4.1 CTUA
SECTION 4: SPECIFICATIONS
Support
Centers
77
492
F
Top View
E
J
Rear View
Air Intake
Heater must be supported
at these points from above
or below.
C
G
D
4 x M10 Captive Nuts Provided
End View
Z
646
B
Gas
Supply
H
Lockout Reset
Flue
Electrical
Cable Entry
168
A
Dimension Data - CTUA (All Models)
Model 22 30 35 40 50 60 75 90 100 115
A
Width
B
Height
C
Support Spacing
D
Support Spacing
E
Support Spacing
F
Centre of Flue
G
Centre of Flue/Air Intake
H
Position of Flue
J
Gas Inlet Position
Z
Length
Flue/Air Intake Pipe Size
Weight kg 84 84 88 92 115 122 160 169 194 203
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm Ø
(in) Ø
1075
(42.3)
610
(24)
450
(17.7)
312
(12.3)
315
(12.4)
240
(9.5)
140
(5.5)
218
(8.6)
150
(5.9)
756
(29.8)
100
(3.9)
1075
(42.3)
610
(24)
450
(17.7)
312
(12.3)
315
(12.4)
240
(9.5)
140
(5.5)
218
(8.6)
150
(5.9)
756
(29.8)
100
(3.9)
1075
(42.3)
610
(24)
450
(17.7)
312
(12.3)
315
(12.4)
240
(9.5)
140
(5.5)
218
(8.6)
150
(5.9)
756
(29.8)
100
(3.9)
1075
(42.3)
610
(24)
450
(17.7)
312
(12.3)
315
(12.4)
240
(9.5)
140
(5.5)
218
(8.6)
150
(5.9)
756
(29.8)
100
(3.9)
1075
(42.3)
895
(35.2)
450
(17.7)
312
(12.3)
315
(12.4)
430
(16.9)
140
(5.5)
211
(8.3)
150
(5.9)
806
(31.8)
100
(3.9)
1075
(42.3)
895
(35.2)
450
(17.7)
312
(12.3)
315
(12.4)
430
(16.9)
140
(5.5)
211
(8.3)
150
(5.9)
806
(31.8)
100
(3.9)
1327
(52.3)
1100
(43.3)
627
(24.7)
312
(12.3)
388
(15.3)
346
(13.6)
225
(8.9)
260
(10.2)
220
(8.7)
756
(29.8)
130
(5.1)
1327
(52.3)
1100
(43.3)
627
(24.7)
312
(12.3)
388
(15.3)
346
(13.6)
225
(8.9)
260
(10.2)
220
(8.7)
756
(29.8)
130
(5.1)
(52.3)
(24.7)
(12.3)
(15.3)
(21.1)
(10.2)
(31.8)
1327
1345
(53)
627
312
388
537
225
(8.9)
260
220
(8.7)
806
130
(5.1)
1327
(52.3)
1345
(53)
627
(24.7)
312
(12.3)
388
(15.3)
537
(21.1)
225
(8.9)
260
(10.2)
220
(8.7)
806
(31.8)
130
(5.1)
5
Page 12
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
4.2 CTUB, CTUC and CTUD
K
End View
CTUB/C (All Models)
115 115
646
1440
115
646
ML
N
End View
CTUC (All Models)
P
679
N
N
End View
CTUD (All Models)
N
Front View
CTUD (And other models fitted with air outlet spigots)
Dimension Data - CTUB, CTUC and CTUD
Model 22 30 35 40 50 60 75 90 100 115
K
CTUB Depth
L
CTUB Height
M
CTUC Height
Inlet & Outlet Duct
N
Spigot Height
Inlet & Outlet Duct
P
Spigot Width
Weight CTUB kg 96 96 100 104 139 146 185 210 228 237
Weight CTUC kg 109 109 113 117 157 163 206 215 251 260
Weight CTUD kg 93 93 97 101 124 131 172 181 200 209
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
1026
(40.4)
610
(24)
610
(24)
534
(21)
709
(27.9)
1026
(40.4)
610
(24)
610
(24)
534
(21)
709
(27.9)
1026
(40.4)
610
(24)
610
(24)
534
(21)
709
(27.9)
1026
(40.4)
610
(24)
610
(24)
534
(21)
709
(27.9)
1026
(40.4)
895
(35.2)
895
(35.2)
817
(32)
707
(27.8)
1026
(40.4)
895
(35.2)
895
(35.2)
817
(32)
707
(27.8)
1076
(42.4)
1100
(43.3)
1100
(43.3)
1024
(40.3)
888
(35)
1076
(42.4)
1100
(43.3)
1100
(43.3)
1024
(40.3)
888
(35)
1076
(42.4)
1380
(54.3)
1431
(56.3)
1233
(48.5)
NOTE: Inlet and outlet duct spigot fitted with 30 mm flange.
888
(35)
1076
(42.4)
1380
(54.3)
1431
(56.3)
1233
(48.5)
888
(35)
6
Page 13
SECTION 4: SPECIFICATIONS
4.3 General Technical Data Table
Model CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115
CTUA With Axial Fan
Total Electrical Load W 210 210 210 210 415 415 510 510 745 745
Run Current A 1. 0 1. 0 1. 0 1. 0 1. 7 2 1. 7 2 1. 9 1. 9 3.2 3.2
Start Current A 1. 4 1. 4 1. 4 1. 4 2.4 2.4 2.8 2.8 4.5 4.5
Air Flow m3/h 3800 4000 4000 4000 5500 5500 7500 7500 11,000 11 ,0 0 0
Sound Pressure Level
at 3 m
CTUB with Centrifugal Fan and CTUC Range with Centrifugal Fan and Duct Inlet
Total Electrical Load W 550 550 550 550 110 0 110 0 110 0 11 00 1650 1650
Normal Run Current A 4.6 4.6 4.6 4.6 11. 0 11.0 11.0 11. 0 15.6 15.6
Normal Start Current A 9.0 9.0 9.0 9.0 13.5 13.5 13.5 13.5 19.2 19.2
Normal Speed Medium Medium Medium Medium Medium Medium Medium Medium Medium Medium
High Run Current A 5.5 5.5 5.5 5.5 14.0 14.0 14.0 14.0 21.0 21.0
High Start Current A 13.6 13.6 13.6 13.6 17.2 17.2 17.2 17.2 25.8 25.8
Air Flow m3/h 3300 3300 3300 3300 5500 5500 6400 6400 9400 9400
Sound Pressure Level
at 3 m
[NR]
dB(A)
[NR]
dB(A)
[51]
56
[59]
59.5
[51]
56
[59]
59.5
[51]
56
[59]
59.5
[51]56[52.1]
[59]
59.5
57.1
[61]
61.5
[52.1]
57.1
[61]
61.5
[52.3]
57.3
[62]
61.8
[52.3]
57.3
[62]
61.8
[52.3]
57.3
[63]
64.2
[52.3]
57.3
[63]
64.2
CTUD Duct Heater with No Fan
**Minimun Air Flow
Required m3/h 3300 3300 3300 3300 5500 5500 6400 6400 9400 9400
Pressure Loss Across
Heat Exchanger Pa 30 30 30 30 30 30 30 30 30 30
Flue and AIr Intake
Flue and Air Intake
Size mm Ø 100 100 100 100 100 100 130 130 130 130
*Maximum Straight
Flue/Air Intake m 7 8 8 10 13 15 15 17 20 20
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.
7
Page 14
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
4.4 Technical Data Table
Appliance Category II
Heat Input
Gross CVkW(Btu/h) x (1000)2793
Heat Input
Net CV
(Btu/h) x (1000)2584
2H/L 3B/P
Model CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115
kW
33
113
30
102
39
133
35
119
48
163
43
147
61
210
55
189
70
238
63
215
95
324
86
292
111
378
100
341
119
405
107
365
134
459
121
414
Approximate
Heat OutputkW(Btu/h) x (1000)2378
Thermostat Limit Thermodisc
CTUA, B/C, D °C 75 75 75 75 75 75 75 75 75 75
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 8.3 8.7 8.5 9.4 9.3 8.5 6.1 6.0 6.2 6.3
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 12.2 12.7 12.5 14.0 13.6 13.2 9.2 9.3 9.2 10.2
Gas Rate
LPG Gas 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 26.6 24.9 25.4 25.9 25.6 26.8 25.6 27.3 25.3 25.9
Gas Rate
LPG Gas 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 18.9 17.4 17.8 19.5 18.4 19.0 18.3 19.4 18.3 18.7
m3/h
ft3/h
m3/h
ft3/h
m3/h
kg3/h
liquid/h
2.6
92
3.03
107
1. 0 1
1. 8 7
3.7
27
92
3.2
112
3.33
117
1. 2 3
2.28
4.5
32
109
3.7
131
4.31
152
1. 4 8
2.75
5.4
39
133
4.5
160
4.78
169
1. 7 7
3.27
6.4
51
174
5.8
206
6.14
217
2.27
4.21
8.3
58
198
6.6
234
6.98
247
2.58
4.79
9.4
78
266
9.0
319
9.49
335
3.51
6.50
12.8
91
310
10.5
371
11.0 6
391
4.09
7. 5 8
14.9
98
334
11.3
398
11.8 6
419
4.39
8.13
16.0
111
379
12.8
451
13.43
474
4.97
9.21
18.1
Gas Rate
m3/h
kg3/h
liquid/h
0.76
1. 8 6
3.2
0.93
2.27
4.0
1. 0 6
2.59
4.5
1. 3 4
3.26
5.7
1. 7 2
4.19
7. 3
Gas rates corrected to standard conditions 1013.25 mbar 15° C.
1. 9 5
4.77
8.3
2.65
6.47
11.3
3.09
7. 5 5
13.2
3.32
8.09
14.1
3.75
9.17
16.0
8
Page 15
SECTION 5: HEATER INSTALLATION
10 mm
Steel
Drop Rod
Washer
Nut
Unistrut
Channel Nut
Cone Point
Set Pin
Window
Clamp
Unistrut
10 mm
Steel
Drop Rod
Nut
Washer
Riv
Nut
5.1 General
Heaters are designed for installation above 2.5 m.
These heaters must be installed within the heated
space. Duct delivery systems are not permitted with
axial fans.
5.2 Handling
All CTU heaters are supplied secured to a wooden
pallet and shrink wrapped. Use the pallet to support
the heater during handling and installation. When
handling or supporting the heater from below,
ensure that the weight is taken at the support points.
Figure 2: Suspension Methods
Insure all suspension hardware
is torqued to a minimum
of 27 Nm (20 ft lbs)
SECTION 5: HEATER INSTALLATION
5.3 Shelf Mounting and Suspension
WARNING
Crush Hazard
Use 10 mm steel drop rod
minimum.
Failure of the supports can
result in death, injury
or property damage.
For typical suspension See Page 9, Figure 2.
Support Points
9
Page 16
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 6: FLUE INSTALLATION
6.1 Flue Installation
Figure 3: Flue and Roof Detail
WARNING
Terminal
Flue
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.
The flue must terminate outside of the building.
Flues and air intakes must be a fully sealed system
and correctly sized for the model. Flues should be
assembled as detailed
on Page 10, Figure 3 through
Page 11, Figure 6. The joints between the flue
terminal 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 and air intakes must be adequately
supported so that the heater does not bear the
weight of the pipes.
For flue termination See Page 10, Figure 3 through
Page 11, Figure 6.
6.2 Type C12, C32 & C62 Appliance
Room Sealed.
The heaters are designed to be installed as room
sealed appliances. The flue and air intake are run as
separate pipes to the special concentric wall or roof
terminal.
See Page 11, Figure 6.
Roof
25 mm Air Gap to
Combustible Material
Figure 4:
Air Intake Terminal Cover
Fold Leg
Down
Fold Foot
Out
Masterflash
Soaker Flashing
or Rain Collar.
Metal Sleeve
Flue
6.3 Type B22 Appliance
The flue must terminate outside the building and be
fitted with a low resistance terminal.
See Page 10, Figure 3 through Page 11, Figure 5.
6.3.1 Air Intake Terminal Cover
For Type B22 appliance installations, an air intake
terminal cover is an available option. The cover is
scored flat sheet metal that must be bent into shape.
See Page 10, Figure 4. Remove and retain the
screws for the air inlet spigot. Use these screws to
attach the cover in position over the spigot.
10
Fold Leg
Down
Fold Foot
Out
Description Part Number
Air Intake Terminal Cover (100mm) F078A
Air Intake Terminal Cover (130mm) F077A
Page 17
Figure 5: Vertical and Horizontal Flue Termination - Type B22 Appliance
Roof Terminal
Masterflash
Flue
Air Intake
Terminal Cover
Vertical
Option
90°
Bend
Flue
Horizontal
Option
Combustible Material)
Masterflash
SECTION 6: FLUE INSTALLATION
Metal Sleeve
(25 mm air gap to
Wall
Terminal
Figure 6: Vertical and Horizontal Flue Termination
Manifold
Air Intake
Vertical
Option
Air Intake
Flue
Horizontal
Option
- Type C12 C32 & C62 Appliances
Roof Terminal
Plastic Cup
Masterflash
Flue
90° Bend
Manifold
Model Concentric Flue Diameter
22-60 Cover (100mm) 150mm
75-115 Cover (130mm) 200mm
Wall
Terminal
Wall
Plate
End View
Max wall thickness
335 mm
The minimum
gap must be
positioned at bottom
11
Page 18
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 7: AIR SUPPLY
7.1 Room Sealed Installation
When installed as a room sealed heater, the air for
combustion is drawn in from outside the building. It
is important to ensure that there is adequate
ventilation to provide air for the distribution fan/s.
7.3 Building Ventilation
Where ventilation is required, air must be taken from
an outside point where it is not likely to be
contaminated or obstructed.
Where natural ventilation is used, suitable ventilation
with outside air at low level must be provided in
7.2 Open Flued Installation
It is important to ensure that there is adequate air
supply at all times for both combustion and heating
requirements in accordance with local and national
codes. When installed in this mode, the air supply to
the heater must also be fitted with a low resistance
terminal to prevent the ingress of debris.
See Page
11, Figure 5.
7.2.1 Heaters Installed Within the Heated Space
Where the volume of the heated space is greater
3
than 4.7 m
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, ventilation will be necessary in accordance
with local and national codes. Ventilation direct to
outside must be provided as follows:
• Heaters up to 70 kW heat input: 5.0 cm2 per kW
of rated heat input
• Heaters above 70 kW heat input: 350 cm2 + 2.5
2
cm
per kW of rated heat input above 70 kW
accordance with
codes.
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 CTU heater.
7.4 Isolated Equipment Rooms
Ventilation must prevent the isolated equipment
room temperature from exceeding 32° C as well as
prevent any negative air pressure within the room.
See Page 12, Figure 7. 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 CTU heater.
Section 7.2.1 and local and national
Figure 7: Heaters Installed in Isolated Equipment Rooms
Manifold
Air Intake
Duct Distribution
System or
Discharge to
Heated Space
Max Temperature 32° C
Room Air Pressure Must Not be Negative.
High Level
Ventilation
Flue
Return Air Duct
from Heated
Space or Fresh
Air from Outside
Low Level
Ventilation
12
Wall
Outside
Wall
Page 19
SECTION 8: OPTIONAL HEATER CONFIGURATIONS
8.1 Distribution Duct Work for CTUB, CTUC and
CTUD Heaters
CTUC heaters have the fans enclosed so that the
heater may be connected to inlet ducting.
CTUD 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 recommended that flexible duct connectors are
used to reduce duct born noises.
When installing CTUD heaters onto ducting force
the fan to run.
Do not rely on the fan thermostat to turn it on.
Any such device must be in parallel with the fan
thermostat so that the fan run-on operation will still
operate.
Contact Roberts-Gordon Europe Ltd. Design
Department for recommendations regarding
duct resistance and design. Tel: +44 (0) 121 506
7700
8.1.1 CTUD Heaters
For CTUD heaters, it is essential that the airflow in
the duct system is at least that specified in the Data
Sheet
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
13, Section 8.1 and Figure 8 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
on Page 6, Section 4.2 and in the correct
Figure 8: Ducting
NOTE: Duct size will be full size of inlet and outlet.
All joints between the heater and duct work should be
made as air tight as possible.
Airflow Indicator
Minimum-
Twice
Dimension
X
Dimension
X
Minimum-
Twice
Dimension
X
Ducting
Ducting
Flexible Flange
13
Page 20
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 9: GAS PIPING
9.1 Connections
Connect the heater to the gas supply ensuring that
WARNING
the final connections are as follows:
• Gas supply pipe work is run in medium or heavy
gauge tubing in compliance with local and
national codes.
• The gas supply pipe is adequately sized to carry
the total volume of gas for the complete
Fire Hazard
Connect gas supply according to Figure 9.
Gas can leak if not installed properly.
Failure to follow these instructions can result in death,
injury or property damage.
installation.
• 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
It is important that the gas supply pipe and the
electrical connections do not support any of the
one pipe size larger than the heater gas
connection.
heater’s weight.
A gas meter is connected to the service pipe by the
gas supply company. An existing meter should be
checked, preferably by the company, to ensure that
IMPORTANT - The complete installation must be
purged and tested for gas soundness in accordance
with local and national codes.
the meter is adequate for the rate of gas supply
required.
Installation pipes must be fitted in accordance with
local and national codes. Pipe work from the meter
to the heater(s) must be of adequate size. Pipes of
smaller size than the heater inlet gas connection
should not be used.
Figure 9: Gas Connection with Stainless Steel Flex Connector
• Hold gas nipple securely
with pipe wrench when
attaching the flex gas
connector.
• Do not twist flexible
gas connector.
• Ensure all joints are
gas tight.
Do not bend flexible
gas connector sharply.
Gas Isolating Valve
Option A:
Stainless Steel
Flex Gas
Connector
Option B:
Medium or Heavy
Gauge Tubing
Gas Connector
Drip Leg
14
Union
Connection
Cap
Page 21
SECTION 10: WIRING AND ELECTRICAL INFORMATION
10.1 Electrical Supply
All heaters need a constant 230 V 50 Hz single
phase supply connected to terminals L, N & Earth.
Polarity "L & N" must be correct. The voltage
between neutral and earth should be 0 and never
exceed 15 volts.
All heaters and controls must be correctly earthed.
All external wiring must comply with the relevant
local codes. Wire specification H05VV-F.
External controls must have the same constant
230 V 50 Hz supply.
10.2.1 Burner Controls (Thermostat)
Controls to operate the burner must be voltage free
contacts connected between terminals 2 & 3 of the
main terminal block.
10.2.2 Positioning Room Thermostats or
ROBERTS GORDON® 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 both cold draughts and the direct path of warm air
from the heater.
SECTION 10: WIRING AND ELECTRICAL INFORMATION
An isolator with a contact separation of at least
3 mm on all poles must be installed adjacent to, but
not attached to, the heater to disconnect all supplies
to the heater and any remote control.
The final connection to the heater should be made
by flexible cable or conduit to the main terminal
2
block on the inside of the heater using 1 mm
cable
on all models.
Models ............................................ Fuse Size
CTUA (All Models) ........................................... 5 A
CTUB & CTUC (Models 22-50)...................... 10 A
CTUB & CTUC (Models 75 - 115) .................. 20 A
CTUD heaters must have the external fan, or its
control connected to Terminal 1 so that the fan runon function at close down operates correctly.
10.2.3 Remote Frost Thermostat
When required, connect to terminals 2 and 3 in the
main terminal block.
Locate within the heated space adjacent to the most
vulnerable equipment that requires protection.
See Page 16, Section 10.3 through Page 17, Section
10. 4.
10.2.4 Remote Fan Controls
The fan will operate automatically providing there is
a constant 230 V supply to the main terminals.
A switch or control wired between terminals L & 1 in
the terminal block 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.
WARNING
Electrical Shock Hazard
Disconnect electrical power before servicing.
Failure to follow these instructions can result in
death or electrical shock.
10.2 Remote Controls
The heater is designed to be operated by controls
installed remote from the heater.
Section 10.3. through Page 17, Section 10.4.
See Page 16,
15
Page 22
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
10.3 CTUA Wiring Diagram (Models 22-60)
IGNITION MODULE
GAS VALVE
BLACK
NO\P(3)
C\P(1)
NC\P(2)
Pressure Switch
Detail
YELLOW
WHITE
1112 7910 8 564
BROWN
WHITE
BLACK
WHITE
YELLOW
BLUE
BROWN
YELLOW
GREEN/YELLOW
RUN
LOCKOUT
23 1
BROWN
PINK
PURPLE
GREY
BLACK
PRESSURE SWITCH
LOCKOUT
RESET
BLUE
BROWN
BROWN
GREEN/YELLOW
BLUE
BROWN
Time Delay Relay
Thermostat Limit
Thermodisc N/C
E
N
L
AXIAL FAN
E
FAN
N
L
COMBUSTION
BLUE
BLUE
BROWN
MAINS FILTER
BROWN
RED
RED
IGNITION MODULE
Plug in Connection to Gas Valve
SENSE
IGNITION
NOTE:
If any of the original wire supplied with
the heater must be replaced, it must be
replaced with wiring material having a
temperature rating of at least 105° C
and 600 volts.
16
BLACK
Honeywell
S4565C 1017 Control
BLACK
N L 1 2 3 7 8
REMOTE FAN ON
LINE
NEUTRAL
GROUND
230 V
1 Ø
50 Hz
SITE WIRING
THERMOSTAT
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
Page 23
10.4 CTUA Wiring Diagram (Models 75-115)
SECTION 10: WIRING AND ELECTRICAL INFORMATION
SENSE
IGNITION
BLACK
GREEN/YELLOW
BROWN
BLUE
BLACK
S 4563 C Honeywell
RUN
BROWN
BROWN
BROWN
Thermostat Limit
Thermodisc N/C
Time Delay Relay
BLUE
BLACK
NO\P(3)
YELLOW
NC\P(2)
Detail
WHITE
C \P(1)
Pressure Switch
GREEN/YELLOW
E
N
L
COMBUSTION FAN
PRESSURE SWITCH
BLUE
BROWN
BLACK
WHITE
YELLOW
PURPLE
GREY
LOCKOUT
RESET
PINK
BLUE
LOCKOUT
BLUE
BROWN
MAINS FILTER
BLUE
BROWN
GREEN/YELLOW
N L 1 2 3 7 8
REMOTE FAN ON
LINE
NEUTRAL
GROUND
THERMOSTAT
E
N
L
AXIAL FAN
E
N
L
AXIAL FAN
SITE WIRING
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
BROWN
RED
NOTE:
If any of the original wire supplied with
the heater must be replaced, it must be
replaced with wiring material having a
temperature rating of at least 105° C
and 600 volts.
230 V
1 Ø
50 Hz
17
Page 24
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
10.5 CTUB/C Wiring Diagram (Models 22-40)
IGNITION MODULE
GAS VALVE
BLACK
NO\P(3)
C\P(1)
NC\P(2)
Pressure Switch
Detail
YELLOW
WHITE
1112 7910 8 564
BLUE
GREEN/YELLOW
BROWN
BROWN
YELLOW
RUN
WHITE
BLACK
WHITE
YELLOW
LOCKOUT
23 1
PINK
GREY
BROWN
PURPLE
BLACK
PRESSURE SWITCH
LOCKOUT
RESET
BLUE
BROWN
BROWN
GREEN/YELLOW
WHITE N
HIGH BLACK
MEDIUM BLUE
LOW RED
Time Delay Relay
Thermostat Limit
Thermodisc N/C
FAN
CENTRIFUGAL
E
FAN
N
L
COMBUSTION
BLUE
BLUE
BROWN
MAINS FILTER
BROWN
RED
RED
IGNITION MODULE
Plug in Connection to Gas Valve
SENSE
IGNITION
NOTE:
Unused speed setting wires for the
centrifugal fan must be isolated and
insulated. If any of the original wire
supplied with the heater must be
replaced, it must be replaced with
wiring material having a temperature
rating of at least 105° C and 600 volts.
BLACK
Honeywell
S4565C 1017 Control
BLACK
N L 1 2 3 7 8
REMOTE FAN ON
LINE
NEUTRAL
GROUND
230 V
1 Ø
50 Hz
SITE WIRING
THERMOSTAT
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
18
Page 25
10.6 CTUB/C Wiring Diagram (Models 50-60)
IGNITION MODULE
SECTION 10: WIRING AND ELECTRICAL INFORMATION
GAS VALVE
BLACK
NO\P(3)
C\P(1)
NC\P(2)
Pressure Switch
Detail
YELLOW
WHITE
1112 7910 8 564
BLUE
BROWN
YELLOW
GREEN/YELLOW
RUN
WHITE
BROWN
BLACK
WHITE
YELLOW
LOCKOUT
23 1
PINK
GREY
BROWN
PURPLE
BLACK
PRESSURE SWITCH
LOCKOUT
RESET
E
N
L
BLUE
BROWN
A
FAN
COMBUSTION
B
Time Delay Relay
BROWN
Thermostat Limit
Thermodisc N/C
CENTRIFUGAL FAN 2
GREEN/YELLOW
WHITE N
HIGH BLACK
MEDIUM BLUE
LOW RED
GREEN/YELLOW
WHITE N
HIGH BLACK
MEDIUM BLUE
LOW RED
CENTRIFUGAL FAN 1
5
6
4
RELAY
8
9
7
BLUE
BLUE
BROWN
RED
BROWN
RED
MAINS FILTER
IGNITION MODULE
Plug in Connection to Gas Valve
SENSE
IGNITION
NOTE:
Unused speed setting wires for the
centrifugal fan must be isolated and
insulated. If any of the original wire
supplied with the heater must be
replaced, it must be replaced with
wiring material having a temperature
rating of at least 105° C and 600 volts.
BLACK
Honeywell
S4565C 1017 Control
BLACK
N L 1 2 3 7 8
REMOTE FAN ON
LINE
NEUTRAL
GROUND
230 V
1 Ø
50 Hz
SITE WIRING
THERMOSTAT
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
19
Page 26
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
10.7 CTUB/C Wiring Diagram (Models 75-115)
SENSE
IGNITION
BLACK
GREEN/YELLOW
BROWN
BLUE
BLACK
S 4563 C Honeywell
RUN
BROWN
BROWN
Thermostat Limit
Thermodisc N/C
BROWN
CENTRIFUGAL FAN 3
models 100-115 only
GREEN/YELLOW
WHITE N
HIGH BLACK
MEDIUM BLUE
LOW RED
CENTRIFUGAL FAN 2
GREEN/YELLOW
WHITE N
HIGH BLACK
MEDIUM BLUE
LOW RED
Time Delay Relay
BLUE
BLACK
NO\P(3)
YELLOW
NC\P(2)
Detail
WHITE
C \P(1)
Pressure Switch
BLUE
GREEN/YELLOW
E
N
L
COMBUSTION FAN
PRESSURE SWITCH
BROWN
BLACK
WHITE
YELLOW
PURPLE
GREY
LOCKOUT
RESET
PINK
BLUE
LOCKOUT
BLUE
BROWN
MAINS FILTER
A
5
6
4
8
B
7
N L 1 2 3 7 8
REMOTE FAN ON
LINE
NEUTRAL
GROUND
THERMOSTAT
GREEN/YELLOW
WHITE N
HIGH BLACK
MEDIUM BLUE
LOW RED
CENTRIFUGAL FAN 1
RELAY
9
SITE WIRING
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
BROWN
RED
NOTE:
Unused speed setting wires for the
centrifugal fan must be isolated and
insulated. If any of the original wire
supplied with the heater must be
replaced, it must be replaced with
wiring material having a temperature
rating of at least 105° C and 600 volts.
20
230 V
1 Ø
50 Hz
Page 27
10.8 CTUD Wiring Diagram (Models 22-60)
IGNITION MODULE
SECTION 10: WIRING AND ELECTRICAL INFORMATION
GAS VALVE
BLACK
NO\P(3)
C\P(1)
NC\P(2)
Pressure Switch
Detail
YELLOW
WHITE
1112 7910 8 564
BLUE
BROWN
YELLOW
GREEN/YELLOW
RUN
WHITE
BROWN
BLACK
WHITE
YELLOW
LOCKOUT
23 1
PINK
GREY
BROWN
PURPLE
BLACK
PRESSURE SWITCH
LOCKOUT
RESET
BLUE
BROWN
BROWN
Time Delay Relay
Thermostat Limit
Thermodisc N/C
E
FAN
N
L
COMBUSTION
BLUE
BLUE
BROWN
MAINS FILTER
RED
RED
BROWN
IGNITION MODULE
Plug in Connection to Gas Valve
SENSE
IGNITION
NOTE:
For external fan wiring,
See Page 23, Section 10.10.
If any of the original wire supplied with the
heater must be replaced, it must be replaced
with wiring material having a temperature
rating of at least 105° C and 600 volts.
BLACK
Honeywell
S4565C 1017 Control
BLACK
N L 1 2 3 7 8
LINE
NEUTRAL
GROUND
230 V
1 Ø
50 Hz
SITE WIRING
THERMOSTAT
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
21
Page 28
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
10.9 CTUD Wiring Diagram (Models 75-115)
SENSE
IGNITION
BLACK
GREEN/YELLOW
BROWN
BLUE
BLACK
S 4563 C Honeywell
RUN
BROWN
BROWN
BROWN
Thermostat Limit
Thermodisc N/C
Time Delay Relay
BLUE
BLACK
NO\P(3)
YELLOW
C \P(1)
Pressure Switch
WHITE
NC\P(2)
Detail
GREEN/YELLOW
E
N
L
COMBUSTION FAN
PRESSURE SWITCH
BLUE
BROWN
BLACK
WHITE
YELLOW
PURPLE
GREY
LOCKOUT
RESET
PINK
BLUE
LOCKOUT
BLUE
BROWN
MAINS FILTER
N L 1 2 3 7 8
LINE
NEUTRAL
GROUND
THERMOSTAT
BROWN
SITE
WIRING
RED
NOTE:
For external fan wiring,
See Page 23, Section 10.10.
If any of the original wire supplied with the
heater must be replaced, it must be replaced
with wiring material having a temperature
rating of at least 105° C and 600 volts.
22
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
230 V
1 Ø
50 Hz
Page 29
SECTION 10: WIRING AND ELECTRICAL INFORMATION
10.10 CTUD External Motor Alternative Wiring
Single Phase Motor
with Load over 7 Amps
NL 12 3
2A
L
N
230 V 50 Hz
supply
Thermostat
230 V
Room
Thermostat
Frost
230 V 50 Hz
Time Switch
Contactor or Relay
Single Phase Motor
with Load Over 7 Amps
Overload protection must
be provided at the motor
or contactor.
RDW 1565
& Optional Thermostat/Time Switch
Three Phase Motor
NL 12 3
Room
2A
N
LLL
2
1
400 V 50 Hz
3 Ø Supply
3
Thermostat
Frost
Thermostat
230 V 50 Hz
Time Switch
230v
Contactor or Relay
400 V 3 Ø
motor
Overload protection must
be provided at the motor
or contactor.
23
Page 30
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 11: COMMISSIONING
Installation, service, commissioning and annual
inspection of the 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. All
components are accessed via the hinged door
secured by a ¼ turn latch. Opening the door
exposes live electrical connections and hot
components.
WARNING
11.1.2 Electrical Checks
All 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 diagrams on Page 16, Section 10.3 through Page
23, Section 10.10.
2. Check the correct fuse size is fitted;
See Page 15, Section 10.1.
11.2 Gas Supply
All aspects of the gas installation including the gas
meter must be inspected, tested for soundness and
purged in accordance with local and national codes.
Ensure that the air is fully purged from the heater
inlet pipe up to the main gas valve inlet test nipple.
Electrical Shock Hazard
Use extreme caution while commissioning.
Failure to follow these instructions can result in
death or electrical shock.
11.1 Pre-Commission Checks
All pre-commission checks must be carried out
before lighting the heater.
Ensure 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 Louvres
Where fitted, the air delivery louvres need to be set
during commissioning to give the required air
distribution.
WARNING
11.3 Mechanical Checks
1. Check that the fan(s) are free to run and
delivery louvres are turned to give required air
deflection.
2. Check that the flue (and air intake for room
sealed) is installed in accordance with these
instructions and local regulations.
3. The thermostat limit thermodisc is preset and
sealed at the factory and is not adjustable.
11.4 Begin Commissioning
11.4.1 Before Operating the Heater
To ensure that all the controls are in safe working
order, operate the heater for the first time with the
isolating gas valve turned off.
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
There will be no ignition of the burner and lockout
will occur, which proves the controls are operating
correctly.
on Page 25, Figure 10.
Cut Hazard
Turn off gas and electrical supply before maintenance.
Fan can start automatically at any time.
Failure to follow these instructions can result in severe
injury or product damage.
24
Page 31
Figure 10: Automatic Burner Control Box Sequence
SECTION 11: COMMISSIONING
Burner sequence for Honeywell S4563 or S4565C
Supply 230 V
Flue Fan
Pressure Switch
Ignition Spark
Start Gas Valve
Flame Signal
NO
P
C
NC
*Purge time begins at pressure switch change over.
**ts=Safety time (S4563C=3 seconds [alternate 5 seconds]; S4565C=5 seconds)
30 Sec. Purge*
ts**
Required Incoming Signals
Signals Output By Control
If at any stage the flame fails, the control will go to "lockout". The red light will illuminate and the
control will need to be manually reset before any further start attempt can be made.
Figure 11: Gas Valve for Heater (Models 22 - 60)
CLOSE
DOWNRUNSTART
End View
Ignition
Output
Flame
Probe
Connection
Regulator
(Under Cover)
Outlet Pressure
Inlet Pressure
Fixing Screw
Ignition Control
(Plugs into Gas Valve)
12 Cable Connector
Gas Inlet
25
Page 32
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
Figure 12: Gas Valve for Heater (Models 75 - 115)
Plug for
Main Gas Valve
Regulator
(Under Cover)
Inlet Pressure
Gas Inlet
Plug for
Main Safety
Gas Valve
Outlet Pressure
11.4.2 Commissioning the Gas Valves (all gases)
11.4.2.1 Check Burner Gas Pressure
1. Loosen 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 for the correct gas and model
on Page 8, Section 4.4.
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 8, Section 4.4 for inlet pressure requirement.
Do not continue to adjust the regulator if the
pressure is not changing.
Gas Outlet
11.5 Combustion Testing
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 meter of the heater. The values of CO
should be between 6.5% to 8.0% for natural gas and
7.0% to 9.1% for LPG dependant upon model.
The CO will be up to 80 ppm (0.008%) dry, air free
dependant upon model. Temperature rise of the flue
gases above ambient should be approximately
160° C to 180° C. Seal test hole in flue after testing.
Pressure Switch:The pressure switch is factory preset for each model and is not adjustable.
2
If the inlet pressure is too low to allow correct burner
pressure setting, then the gas inlet pressure must be
corrected before completing the commission.
Check Gas Rate
1. 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 and tighten the screw of the outlet
pressure tap.
3. Check gas flow rate at gas meter.
26
11.6 Turning Off the Heater
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 electrical isolator for control of
heater. Electrical isolator will switch off the fan.
Heat exchanger could be damaged. Warranty will
not cover damage to the heat exchanger if
operated improperly.
Page 33
11.7 External Controls
External controls may include time switch, room
thermostat and frost thermostat. Operate each
control to ensure that they function correctly. Set the
time switch (if fitted) and room thermostat to the
users’ requirements.
11.8 Complete the Commissioning
Ensure that all covers are fitted correctly and all test
points are properly sealed.
11.9 Instruction to the User
Explain 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
importance of maintaining clearances to
combustibles and the user instructions
on Page 28,
Section 12 through Page 29, Section 12.5 and all
warnings defined in this manual.
SECTION 11: COMMISSIONING
27
Page 34
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 12: USER INSTRUCTIONS
12.1 User Instructions
The CTU heaters are fully automatic and operate
12.3 Common User Controls
12.3.1 Thermostat Limit Thermodisc
from the external controls fitted on site.
The only user controls at the heater are the:
Burner Lockout Reset Button:
See Page 28, Section 12.3.2
Thermostat Limit Thermodisc Reset Button:
See Page 28, Section 12.3.1
These are hand reset devices to give further
protection against fan failure.
WARNING
Electrical Shock Hazard
Disconnect electrical power before servicing.
NOTE: To reset, the heat exchanger must be cool.
Description Part Number
All Models 90412100
Press to reset
WARNING
Failure to follow these instructions can result in
death or electrical shock.
12.2 Heater Operation
When the heater has been switched on by the
remote controls installed on site, the main burner will
automatically turn on.
The burner control box will control the safe ignition
of the flame.
All heaters require a constant gas and electricity
supply which must not be interrupted during the
normal operation of this heater.
Figure 13: Heater Operating Sequence
THERMOSTAT
CALL FOR
HEAT
BURNER
RUN
FAN
ON
ON
ON
2-3 MINUTES
CLOSE
DOWN
RUN ON
Explosion Hazard
If control locks out, do not make more than 3
attempts to restart the heater.
Dangerous gas mixtures can build up.
The fault must be traced and repaired by a
registered installer or service engineer.
Failure to follow these instructions can result in
death, injury or property damage.
12.3.2 Burner Lockout Reset Button
The red warning light at the front of the heater will
illuminate when the control has gone to lockout. This
may be caused by flame failure. Press the reset
button on the back of the heater, (
See Page 5,
Section 4.1), or the remote reset if installed on site.
12.4 Lighting Instructions
12.4.1 To Turn On Heater
1. Ensure that the electrical and gas supplies to
the heater are on. Check that the on site
controls are “ON”.
NOTE: The thermostat setting must be above the
ambient temperature for the heater to operate.
2. The green light will be on and the automatic fir-
ing sequence will begin as described on Page
25, Figure 10. The heater will now operate automatically under the control of the on site controls. Following long shut down periods, the
control may go to lockout.
See Page 28, Sec-
tion 12.3.2.
28
Page 35
12.4.2 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”.
12.5 Simple Fault Finding
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. The thermostat limit thermodisc may have
operated. This may be caused by an interrup
tion of the electrical supply or failure of the
distribution fan.
SECTION 12: USER INSTRUCTIONS
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
If the thermostat limit thermodisc persistently
operates, there is a fault which must be investigated
by a contractor qualified in the installation and
service of gas-fired heating equipment.
12.5.1 Simple Fault Finding (Burner Faults)
If 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. Press in and release the lockout reset button. If
a remote reset is not fitted, a reset button is on
the rear panel of the heater.
See Page 5, Section 4.1.
Lockout should not occur during normal operation of
the heater and indicates there is a fault condition
which must be corrected.
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.
29
Page 36
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 13: SERVICING
13.1 Servicing Instructions
After 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
13.3 Fan/Motor Assembly Maintenance
The main fan bearings are permanently sealed and
do not need lubrication. Before cleaning, turn off gas
and electrical supply. Remove the fan(s) and use a
small brush or duster to clean the fan blades from
each side. Replace fan(s) when done.
heater must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment.
13.3.1 For CTUB & CTUC Centrifugal Fan
Models
CTUB and CTUC models are fitted with thermally
protected three speed fans. The number of fans can
WARNING
be found
air flow for each model can be found on Page 7,
Section 4.3.
For CTUC 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
Cut Hazard
Turn off gas and electrical supply before maintenance.
Fan can start automatically at any time.
Failure to follow these instructions can result in severe
injury or product damage.
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
NOTE 1: After any maintenance or repair work
always test fire the heater in accordance with the
commissioning instructions
on Page 24, Section 11
through Page 27, Section 11.9 to ensure all safety
systems are in working order before leaving the
overload to operate and the fan thermostat to cycle.
All fans on a heater must be set to operate at the
same speed. For Models 50 - 115, they will be
switched using a fan relay built into the heater.
Page 40, Section 16.8.2.
heater to operate. Minor faults may be traced by
using the troubleshooting charts
on Page 32,
Section 15 through Page 34, Section 15.4.
13.4 Heat Exchanger Maintenance
The heat exchanger will remain clean unless a
problem has developed with combustion. Inspect the
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.
heat exchanger. Look for signs of overheating at the
front tubes which may indicate burner over firing or
persistently low air flows.
on Page 41, Section 16.9 and the standard
See
NOTE 3: Inspect all suspended components and
hardware. Insure that they are in good condition,
properly tightened, and corrosion free.
13.2 Burner Maintenance
1. Open the hinged door and remove the burner
compartment cover.
See Page 36, Section
16.2.
2. Clean any deposits from the main burner which
may have formed in the injectors or venturi of
the burner.
See Page 36, Section 16.2.
3. Remove the ignition electrode and flame probe.
Check condition of ignition electrode and flame
probe. Clean off any deposits which may have
been formed, check condition of ceramic
insulators. Replace as necessary.
30
13.5 Gas Control Valve Maintenance
No regular maintenance is required on these
devices. To change gas control valves,
See Page
35, Step 16.1 and Page 39, Section 16.5.
Do not repair or disassemble on site.
Replace faulty gas valves with genuine
®
ROBERTS GORDON
replacement parts.
13.6 Flue Fan
The flue fan should not require maintenance.
However, if the air pressure switch is causing burner
lockout, then remove the flue fan from the vent box
by unscrewing the screw at the outlet flange and the
flue fan mounting plate (
See Page 38, Section 16.4).
Ensure that the fan is free to run and that the fan
wheel is clean.
Page 37
SECTION 14: CONVERSION BETWEEN GASES
14.1 General
Conversion between gasses will require a change of
burner injectors and the gas valve re-commissioning
to the new conditions.
14.2 Burner Conversion
Conversion of the burner assembly from one gas to
the other is the same for all types of heaters.
1. Remove the burner compartment cover as
shown
on Page 36, Section 16.2.
2. Remove the connection between the gas valve
outlet and the manifold.
See Page 35, Section
16.1 for gas valve removal.
3. Remove the manifold from the burner assembly
by removing the screws at the top and bottom.
See Page 36, Section 16.2.1.
4. Remove the main burner injectors.
5. Replace with the injectors for the new gas
ensuring a gas tight seal.
6. Refit all components in reverse order.
SECTION 14: CONVERSION BETWEEN GASES
14.3 Gas Valves
All gas valves used on the CTU have pressure
regulators that may be set to operate on natural gas
or LPG.
Conversion is carried out by re-setting the burner
pressure to the value in the data table during
commissioning.
See Page 8, Section 4.4.
Ensure that the gas inlet pressure to the heater is
correct for the new gas, and that the gas supply has
been purged of the old gas.
31
Page 38
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 15: TROUBLESHOOTING
15.1 General
Installation Code and Annual Inspections: All
WARNING
installations and service of
GORDON
contractor qualified in the installation and service
of equipment sold and supplied by RobertsGordon and conform to all requirements set forth
in the
applicable governmental authorities pertaining to
the installation, service and operation of the
equipment.
Explosion Hazard
Installation must be done by a registered installer/
contractor qualified in the installation and service of
gas-fired heating equipment or your gas supplier.
Failure to follow these instructions can result in death,
injury or property damage.
To help facilitate optimum performance and safety,
Roberts-Gordon recommends that a qualified
contractor annually inspect your
GORDON
where necessary, using only replacement parts
sold and supplied by Roberts-Gordon.
®
equipment must be performed by a
ROBERTS GORDON® manuals and all
ROBERTS
®
equipment and perform service
ROBERTS
Start
Are gas & electrical
supplies on?
Ye s
Is Red lockout
warning light on?
No
With external controls on,
does the burner continue
to fire?
Ye s
Ye s
Is distribution air fan
operating?
No
Ye s
No
No
Turn on supplies.
Use 15.2 to test burner.
Check limt thermostat(s);
Reset.
Check time delat relay. Is
there 230 V accross brown
and blue wires?
Ye s
No
No
Use 15.2 to test burner.
Check for mis-wiring.
Change time delay relay.
Ye s
Heater Operating
TROUBLESHOOT ENDS.
No
If problems persist, contact
ROBERTS GORDON
Tel: +44(0)121 506 7709
www.rg-inc.com
®
at
For your safety and optimum heater performance, use only ROBERTS GORDON® replacement parts.
Conduct Commissioning procedure as shown on Page 24, Section 11.
32
Page 39
15.2 Troubleshooting For Automatic Ignition Burner Systems
There are two burner controls used: Honeywell S4563C and
S4565C. They both have similar operating sequences. To
measure flame current, connect a 0 - 50 μA DC meter in
series with the flame probe. If the meter reads negative
values, then reverse the test leads.
SECTION 15: TROUBLESHOOTING
WARNING
Electrical Shock Hazard
Start
Are gas & electrical
supplies on?
Ye s
Is the green light on?
Ye s
Is red lockout light on?
No
Does flue fan run?
No
No
Ye s
No
Turn on supplies.
Are external controls on?
Press in lockout reset button
on rear of heater or remote
reset button if fitted.
Is 230 V supply at fan
connections?
Burner control faulty or plug
in connections faulty. Repair
or replace as necessary
No
Has the thermostat limit
thermodisc operated or light
Ye s
faulty? Reset or replace as
necessary.
Ye s
Flue fan faulty replace
Do not touch ignition components.
Voltage from ignition components is high.
Failure to follow these instructions can
result in death or electrical shock.
Ye s
Does air pressure switch
change over?
Ye s
Wait 30 - 40 seconds.
Is ignition spark operating?
Ye s
Does the flame light?
Ye s
Is red lockout light on?
No
Heater Operating
TROUBLESHOOT ENDS.
Check for too much flue/air inlet
duct. Check for blockage in
No
No
No
Ye s
No
combustion air circuit.
Check for faulty air pressure
switch. See section 16.5.
Is HT lead okay and
connected?
Is spark electrode okay?
Is the gas valve operating?
To test valve,
see Section 15.4.
Is the flame current at
least 1 µAmp DC when
the flame lights?
If problems persist, contact
ROBERTS GORDON
Tel: +44(0) 121 506 7709
www.rg-inc.com
Ye s
No
No
Ignition control faulty
replace.
See Section 15.6.
Replace valve.
Trace fault in supervision
system. See Section 16.3.
For your safety and optimum heater performance,
®
®
at
use only ROBERTS GORDON
replacement parts.
Conduct Commissioning procedure as shown
on Page 24, Section 11.
33
Page 40
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
15.3 Troubleshooting for Flame Supervision System
START
Connect a DC ammeter in
series with the flame probe.
Is the green light on and
at least 1 µA DC flame
current?
Ye s
Is there a current flowing in the
flame probe circuit with no
flame present?
No
Does lockout occur when
there is a flame present?
No
Heater Operating
TROUBLESHOOT ENDS.
No
Ye s
Ye s
No
Use section 15.1 to
trace the fault.
Is the connecting lead
damaged? Is the flame probe
damaged or touching earthed
components?
Is inlet burner gas pressure
correct? Is live and neutral
polarity correct? Is
flame probe circuit correct?
No
Repair or replace as
necessary.
If problems persist, contact
ROBERTS GORDON
Tel: +44(0) 121 506 7709
www.rg-inc.com
®
at
Repair or replace as
Ye s
Ye s
necessary.
Control box faulty.
Replace with correct type.
NOTE: Minimum flame probe current 1 μA DC. Typical flame probe current 3-5 μA DC.
15.4 Troubleshooting for Solenoid Valves
START
Is 230 V at the valve
terminals at the
appropriate time.
Ye s
Is gas pressure at inlet of the
valve correct for gas type?
Note pressure found.
Ye s
Does gas pressure at outlet
of the valve rise when
valve turns on?
Ye s
Ye s
Does gas pressure at
outlet of valve return to zero or
lower when valve turns off?
Ye s
Valve Operating
TROUBLESHOOT ENDS.
No
No
No
No
No
Fault elsewhere
Fault elsewhere
Valve faulty.
Replace with one of
correct type.
Valve faulty.
Replace with one of
correct type.
If problems persist, contact
ROBERTS GORDON
Tel: +44(0) 121 506 7709
www.rg-inc.com
®
at
34
Page 41
SECTION 16: REMOVAL AND REPLACEMENT PARTS
See warnings and notes on Page 30, Section 13
before removing or replacing parts.
Burner Components
All serviceable burner parts are accessed by the
door on the right side of the heater. Use a
screwdriver to turn the latch 90°.
See Page 5,
Section 4.
16.1 Gas Valve
Remove the gas supply pipe at the heater inlet.
16.1.1
Models 22 - 60
Disconnect
wire harness
Remove
fixing
screw
Unplug
control
from
valve
SECTION 16: REMOVAL AND REPLACEMENT PARTS
Description Part Number
Gas Valve VR4105A 90033403
Ignition Control 90434010
16.1.2
Models 75 - 115
Unplug
electrical lead.
(rectifier harness)
Ignition
Control
Step 1
Unscrew
gas pipe
from the
valve inlet.
Unscrew valve from the
Description Part Number
Gas Valve VR4605 90033404
Ignition Control 90434020
unscrew the fixing screws for
the inlet and outlet flanges.
16.1.3 All Models
Replace in reverse order. Verify that the gas flow
direction of the valve is correct. Use a minimum
amount of gas seal on the thread joint. Re-use the
"O" ring seal in the outlet flange where fitted. Check
that all the joints are leak free. Reset gas valve.
See
Ignition
Control
Step 2
burner manifold
or
Page 26, Section 11.4.2.
IT IS IMPORTANT THAT ONLY THE CORRECT
GAS VALVES SPECIFIED FOR EACH MODEL
TYPE ARE USED WHEN REPLACING THESE
CONTROLS.
35
Page 42
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
Unscrew
Injectors
Manifold
16.2 Burner Compartment
The burner compartment is a sealed
compartment. Following any work,
re-seal the compartment with the gas
pipe rubber seal fully in place and all
screws fitted and tight.
16.2.1
Burner Injectors
Ensure gas tight fitting of injectors.
Ensure correct alignment with burners.
Ensure all pipe joints are gas tight.
Burner
compartment
cover
Flame probe
Viewing port
for flame probe
Remove flexible
air duct from spigot
Ignition electrode
Viewing port
for ignition electrode
Remove
access plate
Rubber Seal
Remove screws and
pull off burner cover
Manifold
Remove manifold
screws and pull
out manifold
Burners
Injectors
Burner
venturi
Burner
Screws
Marking
MODEL CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115
Injector Quantity 5 5 6 7 9 11 12 14 15 17
Natural Gas (G20) and (G25)
Injector size mm Ø 2.08 2.25 2.25 2.25 2.25 2.25 2.71 2.71 2.71 2.71
in Ø 0.0819 0.0886 0.0886 0.0886 0.0886 0.0886 0.1067 0.1067 0.1067 0.1067
Marking 45 225 225 225 225 225 36 36 36 36
RG P/N 91930045 91930225 91930225 91930225 91930225 91930225 91930036 91930036 91930036 91930036
LPG Gas Propane (G31) and LPG Gas Butane (G30)
Injector size mm Ø 1. 2 5 1. 4 0 1. 4 0 1. 4 0 1. 4 0 1. 3 5 1. 5 1 1. 5 1 1. 5 1 1. 5 1
Marking 125 54 54 54 54 135 53 53 53 53
RG P/N 91930125 91930054 91930054 91930054 91930054 91930135 91930053 91930053 91930053 91930053
in Ø 0.0492 0.0551 0.0551 0.0551 0.0551 0.0531 0.0594 0.0594 0.0594 0.0594
36
Page 43
16.3 Ignition Electrode and Flame Probe
Burners
SECTION 16: REMOVAL AND REPLACEMENT PARTS
Thermostat
Limit
Thermodisc
Flame
Probe
Burner Compartment
Front Views
Ignition
Electrode
Burners
.120
(3 mm)
spark
gap
Remove all
burner compartment
screws to remove
the burner
compartment and
access the
Front View.
Flame
Probe
Remove
Screw
Ignition
Electrode
To replace the ignition electrode or flame probe, remove the electrical lead and screw.
Pull out from mounting. Refit in reverse ensuring that the gap to burner is as shown in the
front view of the burner compartment.
Description Part Number
Spark Electrode 90427411
Automatic Ignition Flame Probe 90439300
Burners (all models except CTU-40) 92000000
Burners - CTU-40 92000001
37
Page 44
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
16.4 Flue Fan
Rear Panel
Flue Adapter
Hole
Vent Box
to Flue Fan
screws
Remove screws securing outlet
flange to the flue adapter.
Vent Box
Screws
Gasket
Mounting Plate
to Flue Fan
Screws
Mounting
Plate
Vent Box
Flue
Outlet
Adapter
Gasket
Flue Fan
Disconnect
electrical connections
at plug in tabs.
Mounting Plate
to Vent Box
Screws
Gasket
Air Plate
Remove screws securing flue
fan mounting plate to vent box.
Remove screws securing
mounting plate to fan.
Refit in reverse.
Use new gaskets.
Ensure sealed joints.
Ensure mounting plate orifice is
clear and not obstructed.
MODEL CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115
Flue Fan To ri n D S A
RG P/N 90710430 90710430 90710430 90710430 90710440 90710440 90710001 90710001 90710001 90710450
Air mm Ø
Plate in Ø
RG P/N 110 1113 9 11 0113 8 110 114 0 11 01113 7 110 1113 6 110 1113 5 110111 34 11 01113 3 110 1113 2 110 1113 1
508-128
077272
47.6
1.875
To r i n D SA
508-128
077272
53.1
2.09
Tor in DSA
508-128
077272
60.7
2.39
Tor in DSA
508-128
077272
69.1
2.72
To r i n D SA
524-202
077273
60.7
2.39
Tor in DSA
524-202
077273
69.9
2.75
AO Smith
JFIG098NS
97.0
3.82
AO Smith
JFIG098NS
103 .6
4.08
AO Smith
JFIG098NS
110 . 5
4.35
To r i n D S F
146-052
077274
152.4
6
IT IS IMPORTANT THAT ONLY THE CORRECT FLUE FAN SPECIFIED FOR EACH MODEL TYPE IS
USED WHEN REPLACING THESE ITEMS.
Carry out a commission after working on or changing a flue fan. See Page 28, Section 12.
38
Page 45
16.5 Pressure Switch
Pull off 3 way connector. Spring open plastic clips of
mounting cradle. Replace with correct type of
pressure switch for model. The pressure switches
are colour coded for each pressure setting.
WARNING
Carbon Monoxide Hazard
Use correct pressure switch specified for each model.
Use of incorrect pressure switch could cause unsafe
condition.
Failure to follow these instructions can result in
death or serious injury.
SECTION 16: REMOVAL AND REPLACEMENT PARTS
Carry out a commission after working on or
changing a pressure switch.
See Page 24, Section
11 .
Pressure
Switch
RG P/N 90439801 90439810 90439804 90439803 90439810 90439802 90439811 90439807 90439811 90439807
Colour
Code
Set Point
mbar
in wc 0.23 0.37 0.47 0.41 0.35 0.32 0.72 0.68 0.72 0.68
CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115
pink grey white grey grey yellow grey brown grey brown
0.57 0.92 1. 1 7 1. 0 2 0.87 0.80 1. 7 9 1. 6 9 1. 7 9 1. 6 9
39
Page 46
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
16.6 Ignition Control
IT IS IMPORTANT THAT ONLY THE CORRECT
IGNITION CONTROL SPECIFIED FOR EACH
MODEL TYPE IS USED WHEN REPLACING
THESE ITEMS.
16.6.1 S4565C Models 22 to 60
This control plugs onto the gas valve. Pull out 12 pin
electrical connection. Pull out ignition cable and
flame probe cable noting their positions
Release screw securing control to gas valve
Refit in reverse. Ensure correct location of ignition
and flame probe cables. Ensure that the earth
connection is made directly to the earth point on the
gas valve.
16.6.2 S4563C Models 75 to 115
This control is mounted at the electrical mounting
plate. Pull out the 3 cable connectors.
Pull out ignition cable, ignition earth and flame probe
cable noting their positions. Remove the screws.
Refit in reverse. Ensure correct location of ignition
and flame probe cables.
16.7 CTUA Axial Fan/Guard/Motor Assembly
The axial fan unit for the CTUA heater is
supplied completely assembled and balanced.
• 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 16,
Section 10.3 through Page 17, Section 10.4 wir-
ing diagrams
• Use only genuine ROBERTS GORDON
®
replacement parts.
16.8 CTUB & CTUC Centrifugal Fan/Guard/Motor
Assembly
The direct drive fan/s for the CTUB & CTUC range is
supplied as a complete assembly. Take careful note
of the electrical connections of the fan before
disconnecting from the terminals.
For the CTUC 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.
16.8.1 Fan Removal and Replacement
20 mm x 5 mm Adhesive Seal
is applied to the flange.
16.7.1 Fan Removal
Description Part Number
Axial Fan 16 in. 90710418
Axial Fan 500 mm. 90710419
and Replacement
Remove the four screws
and rubber washers.
16.7.2 To Replace the Fan Assembly
To replace the fan assembly, reverse the procedure
shown above. Fit rubber washers to the guard
mountings to reduce vibration.
Description Part Number
Torin Fan DDC 270-270 A047
Torin Fan DDC 241-241 A049
Remove the fan by removing the fixing screws while
supporting the weight of the fan (approx. 19 kg).
16.8.2 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 as
shown
on Page 41, Figure 14.
• Strictly comply with the colour code of the fan
wires to ensure correct operation.
See Page 18,
Section 10.5 through Page 20, Section 10.7
wiring diagrams.
40
Page 47
• 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.
Figure 14: Centrifugal Fan Orientation
SECTION 16: REMOVAL AND REPLACEMENT PARTS
• Set all fans to operate at the same speed.
CTUB/C 22-40 CTUB/C 50-90 CTUB/C 100-115
16.9 Fan Data
MODEL CTU-22 CTU-30 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115
Axial Fan Type
CTUA Models
RG P/N
Quantity 1 1 1 1 1 2 2 2 2
Fan Ratin g
(Watts per Fan)
Centrifugal Fan Type
CTUB/C Models
RG P/N A049 A049 A049 A049 A049 A047 A047 A047 A047
Quantity 1 1 1 2 2 2 2 3 3
Normal Fan Rating (W) 11 0 0 11 00 110 0 11 00 110 0 1200 1200 1200 1200
High Fan Rating (W) 1400 1400 1400 1400 1400 1700 1700 1700 1700
EBM
S4E420
AA06-02
EBM
S4E420
AA06-02
EBM
S4E420
AA06-02
Ma-Vib
V02-C100
Ma-Vib
V02-C100
EBM
S4E420
AA06-02
EBM
S4E420
AA06-02
Ma-Vib
V02-C100
Ma-Vib
V02-C100
90710418 90710418 90710418 90710419 90710419 90710418 90710418 90710419 90710419
160 160 160 370 370 160 160 370 370
To r in
241-241
To ri n
241-241
To r in
241-241
To ri n
241-241
To r in
241-241
To ri n
270-270
To ri n
270-270
To r in
270-270
To ri n
270-270
41
Page 48
Page 49
Page 50
Page 51
SECTION 16: REMOVAL AND REPLACEMENT PARTS
Attach this information to the wall near the ROBERTS GORDON® heater
®
Read the Installation, Commissioning, Operation and Service Manual thoroughly before installation, operation or service.
OPERATING INSTRUCTIONS
1. STOP! Read all safety instructions on this information sheet.
2. Open the manual gas valve in the heater supply line.
3. Turn on electric power to the heater.
4. Set the thermostat to desired setting (above ambient temperature).
The automatic starting sequence begins.
NOTE: Following long shutdown periods, the burner control may go to
to 'LOCKOUT' during the start sequence. Push the reset button to
recommence firing. Contact service department if 'LOCKOUT'
continues (see manual for details).
TO TURN OFF THE HEATER
1. Turn the thermostat/time switch to 'OFF'. The burner will turn 'OFF'
immediately, but fans will continue to cool heat exchanger until the fan
thermostat switches off.
IF THE HEATER WILL NOT OPERATE, TO ENSURE YOUR SAFETY,
FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER
1. Set the thermostat to off or the lowest setting.
2. Turn off electric power to the heater.
3. Turn off the manual gas valve in the heater supply line.
4. Call your registered installer/contractor qualified in the installation
and service of gas-fired heating equipment.
Installation Clearances
Roof Terminal
WARNING
Fire Hazard
Some objects can catch fire or explode when placed
close to heater.
Keep all flammable objects, liquids and vapors the
required clearances to combustibles away from heater.
Failure to follow these instructions can result in death,
injury or property damage.
Clearances to Combustibles
Air
Intake
Wall
Terminal
Flue
60 cm
15 cm
3 m
50 cm
15 cm
50 cm**
30 cm
2.5 - 3.5 m*
**80 cm is necessary to service heater.
*Heaters may be mounted at a higher level if destratification
fans and/or turn down nozzles are installed.
Roberts-Gordon Europe Limited
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands WS10 7SH UK
Telephone: +44(0)121 506 7700
Installation Code and Annual Inspections:
All installations and service of ROBERTS GORDON® equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts-Gordon and
conform to all requirements set forth in the ROBERTS GORDON
facilitate optimum performance and safety, Roberts-Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON
using only replacement parts sold and supplied by Roberts-Gordon.
For installations at elevations above 2000' (610 m), the appliance shall be derated 4% for each 1000' (305 m) of elevation above sea level.
Further Information:Applications, engineering and detailed guidance on systems design, installation and equipment performance is available through ROBERTS GORDON® representatives.
Please contact us for any further information you may require, including the Installation, Commissioning, Operation and Service Manual.
These products are not for residential use.
© 2007 Roberts-Gordon, LLC www.rg-inc.com Printed in U.S.A. P/N 91040028 Rev B
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
®
manuals and all applicable governmental authorities pertaining to the installation, service and operation of the equipment. To help
Roberts-Gordon, LLC
1250 William Street
P.O. Box 44
Buffalo, NY 14240-0044 USA
Telephone: 716.852.4400
Fax: 716.852.0854
Toll Free: 800.828.7450
®
equipment and perform service where necessary,
45
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