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CTU 40

Roberts Gorden CTU 35, CTU 22, CTU 40, CTU 50, CTU 60 Installation, Commissioning, Operation & Service Manual

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Page 1
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. Leave the building.
6. Immediately call your local gas supplier after leaving the building. Follow the gas suppliers instructions.
7. If you cannot reach your gas supplier, call the Fire Department.
Fire Hazard
Do not store or use petrol or other flammable vapours and liquids in the vicinity of this or any other appliance.
Some objects will catch fire or explode when placed close to heater.
Failure to follow these instructions can result in death, injury or property damage.
WARNING
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.
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.
© Copyright 2007 Roberts-Gordon, LLC
Quality in Any Language™
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
Combat
®
Installation, Commissioning,
Operation & Service Manual
Model CTU
22 to 115
P/N X407UK Rev G 10/07
Tubular Unit Heaters
Page 2
Page 3
© 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.
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
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
1
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.
Page 8
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
2
SECTION 1: HEATER SAFETY
Your Safety is Important to Us! This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnings in these sections.
Installation, service and annual inspection of heater must be done by a registered installer/contractor qualified in the installation and service of gas-fired heating equipment.
Read this manual carefully before installation, operation, or service of this equipment.
This heater is designed for heating non-residential indoor spaces. Do not install in residential spaces. These instructions, the layout drawing, local codes and ordinances, and applicable standards that apply to gas piping, electrical wiring, venting, etc. must be thoroughly understood before proceeding with the installation.
SECTION 2: INSTALLER RESPONSIBILITY
• To install the heater, as well as the gas and 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.
2.2 Corrosive Chemicals
CAUTION
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.
Roberts-Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation; this is entirely the responsibility of the installer. It is essential that the contractor, the sub-contractor, or the owner identifies the presence of combustible materials, corrosive chemicals or halogenated hydrocarbons* anywhere in the premises.
* Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These com
­pounds are frequently used in refrigerants, cleaning agents, solvents, etc. If these compounds enter the air supply of the burner, the lifespan of the heater compo
­nents will be greatly reduced. Warranty will be invalid if the heater is exposed to halogenated hydrocarbons.
2.3 National Standards and Applicable 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.
Page 9
SECTION 3: CRITICAL CONSIDERATIONS
3
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.
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.
3.8 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.
Page 10
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.
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
4
Figure 1: Installation Clearances and Clearances to Combustibles
Wall
Terminal
Roof Terminal
Air
Intake
Flue
50 cm 50 cm**
30 cm
15 cm
Clearances to Combustibles
15 cm
2.5 - 3.5 m*
3 m
60 cm
Installation Clearances
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 2.5 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 and/or turn down nozzles are installed.
**80 cm is necessary to service heater.
Page 11
SECTION 4: SPECIFICATIONS
5
SECTION 4: SPECIFICATIONS
4.1 CTUA
A
B
Rear View
End View
Z
646
168
Gas Supply
F
G
H
Top View
J
E
C
D
77
Heater must be supported at these points from above or below.
492
Support Centers
4 x M10 Captive Nuts Provided
Lockout Reset
Electrical Cable Entry
Air Intake
Flue
Model 22 30 35 40 50 60 75 90 100 115
A
Width
mm
(in)
1075
(42.3)
1075 (42.3)
1075
(42.3)
1075
(42.3)
1075
(42.3)
1075
(42.3)
1327
(52.3)
1327
(52.3)
1327
(52.3)
1327
(52.3)
B
Height
mm
(in)
610 (24)
610
(24)
610
(24)
610 (24)
895
(35.2)
895
(35.2)
1100
(43.3)
1100
(43.3)
1345
(53)
1345
(53)
C
Support Spacing
mm
(in)
450
(17.7)
450
(17.7)
450
(17.7)
450
(17.7)
450
(17.7)
450
(17.7)
627
(24.7)
627
(24.7)
627
(24.7)
627
(24.7)
D
Support Spacing
mm
(in)
312
(12.3)
312
(12.3)
312
(12.3)
312
(12.3)
312
(12.3)
312
(12.3)
312
(12.3)
312
(12.3)
312
(12.3)
312
(12.3)
E
Support Spacing
mm
(in)
315
(12.4)
315
(12.4)
315
(12.4)
315
(12.4)
315
(12.4)
315
(12.4)
388
(15.3)
388
(15.3)
388
(15.3)
388
(15.3)
F
Centre of Flue
mm
(in)
240
(9.5)
240
(9.5)
240
(9.5)
240
(9.5)
430
(16.9)
430
(16.9)
346
(13.6)
346
(13.6)
537
(21.1)
537
(21.1)
G
Centre of Flue/Air Intake
mm
(in)
140
(5.5)
140
(5.5)
140
(5.5)
140
(5.5)
140
(5.5)
140
(5.5)
225
(8.9)
225
(8.9)
225
(8.9)
225
(8.9)
H
Position of Flue
mm
(in)
218
(8.6)
218
(8.6)
218
(8.6)
218
(8.6)
211
(8.3)
211
(8.3)
260
(10.2)
260
(10.2)
260
(10.2)
260
(10.2)
J
Gas Inlet Position
mm
(in)
150
(5.9)
150
(5.9)
150
(5.9)
150
(5.9)
150
(5.9)
150
(5.9)
220
(8.7)
220
(8.7)
220
(8.7)
220
(8.7)
Z
Length
mm
(in)
756
(29.8)
756
(29.8)
756
(29.8)
756
(29.8)
806
(31.8)
806
(31.8)
756
(29.8)
756
(29.8)
806
(31.8)
806
(31.8)
Flue/Air Intake Pipe Size
mm Ø (in) Ø
100
(3.9)
100
(3.9)
100
(3.9)
100
(3.9)
100
(3.9)
100
(3.9)
130
(5.1)
130
(5.1)
130
(5.1)
130
(5.1)
Weight kg 84 84 88 92 115 122 160 169 194 203
Dimension Data - CTUA (All Models)
Page 12
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
6
4.2 CTUB, CTUC and CTUD
115 115
End View
CTUB/C (All Models)
115
End View
CTUC (All Models)
End View
CTUD (All Models)
Front View
CTUD (And other models fitted with air outlet spigots)
N
N
646
P
N
ML
N
K
1440
679
646
Model 22 30 35 40 50 60 75 90 100 115
K
CTUB Depth
mm
(in)
1026
(40.4)
1026
(40.4)
1026
(40.4)
1026
(40.4)
1026
(40.4)
1026
(40.4)
1076
(42.4)
1076
(42.4)
1076
(42.4)
1076
(42.4)
L
CTUB Height
mm
(in)
610
(24)
610 (24)
610 (24)
610
(24)
895
(35.2)
895
(35.2)
1100
(43.3)
1100
(43.3)
1380
(54.3)
1380
(54.3)
M
CTUC Height
mm
(in)
610 (24)
610 (24)
610
(24)
610 (24)
895
(35.2)
895
(35.2)
1100
(43.3)
1100
(43.3)
1431
(56.3)
1431
(56.3)
N
Inlet & Outlet Duct Spigot Height
mm
(in)
534 (21)
534 (21)
534
(21)
534 (21)
817
(32)
817 (32)
1024
(40.3)
1024
(40.3)
1233
(48.5)
1233
(48.5)
P
Inlet & Outlet Duct Spigot Width
mm
(in)
709
(27.9)
709
(27.9)
709
(27.9)
709
(27.9)
707
(27.8)
707
(27.8)
888 (35)
888 (35)
888 (35)
888 (35)
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
Dimension Data - CTUB, CTUC and CTUD
NOTE: Inlet and outlet duct spigot fitted with 30 mm flange.
Page 13
SECTION 4: SPECIFICATIONS
7
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 00
Sound Pressure Level
at 3 m
[NR]
dB(A)
[51]
56
[51]
56
[51]
56
[51]56[52.1]
57.1
[52.1]
57.1
[52.3]
57.3
[52.3]
57.3
[52.3]
57.3
[52.3]
57.3
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 0 110 0 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)
[59]
59.5
[59]
59.5
[59]
59.5
[59]
59.5
[61]
61.5
[61]
61.5
[62]
61.8
[62]
61.8
[63]
64.2
[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.
Page 14
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
8
4.4 Technical Data Table
Appliance Category II
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
Heat Input
Gross CVkW(Btu/h) x (1000)2793
33
113
39
133
48
163
61
210
70
238
95
324
111
378
119
405
134 459
Heat Input
Net CV
kW
(Btu/h) x (1000)2584
30
102
35
119
43
147
55
189
63
215
86
292
100 341
107 365
121 414
Approximate
Heat OutputkW(Btu/h) x (1000)2378
27 92
32
109
39
133
51
174
58
198
78
266
91
310
98
334
111
379
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
m3/h
ft3/h
2.6 92
3.2 112
3.7
131
4.5
160
5.8
206
6.6
234
9.0 319
10.5 371
11. 3 398
12.8 451
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
m3/h
ft3/h
3.03 107
3.33 117
4.31 152
4.78 169
6.14 217
6.98 247
9.49 335
11. 06 391
11.8 6 419
13.43 474
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
m3/h
kg3/h
liquid/h
1. 0 1
1. 8 7
3.7
1. 2 3
2.28
4.5
1. 4 8
2.75
5.4
1. 7 7
3.27
6.4
2.27
4.21
8.3
2.58
4.79
9.4
3.51
6.50
12.8
4.09
7. 5 8
14.9
4.39
8.13
16.0
4.97
9.21
18.1
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
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
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
Gas rates corrected to standard conditions 1013.25 mbar 15° C.
Page 15
SECTION 5: HEATER INSTALLATION
9
SECTION 5: HEATER INSTALLATION
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.
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.
Figure 2: Suspension Methods
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
Support Points
Insure all suspension hardware is torqued to a minimum of 27 Nm (20 ft lbs)
Page 16
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
10
SECTION 6: FLUE INSTALLATION
6.1 Flue Installation
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.
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.
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.
Figure 3: Flue and Roof Detail
Roof
Flue
Terminal
Metal Sleeve
Masterflash
Soaker Flashing
or Rain Collar.
Flue
25 mm Air Gap to
Combustible Material
Figure 4:
Fold Leg
Down
Fold Foot
Out
Fold Leg
Down
Fold Foot
Out
Description Part Number
Air Intake Terminal Cover (100mm) F078A Air Intake Terminal Cover (130mm) F077A
Air Intake Terminal Cover
Page 17
SECTION 6: FLUE INSTALLATION
11
Figure 5: Vertical and Horizontal Flue Termination - Type B22 Appliance
Wall Terminal
Air Intake
Terminal Cover
Flue
Masterflash
Masterflash
Roof Terminal
Vertical Option
Horizontal Option
90° Bend
Flue
Metal Sleeve
(25 mm air gap to
Combustible Material)
Figure 6: Vertical and Horizontal Flue Termination
Wall Plate
Wall Terminal
Flue
Roof Terminal
90° Bend
Flue
Air Intake
Air Intake
Manifold
Manifold
Vertical Option
Horizontal Option
Plastic Cup
Masterflash
The minimum
gap must be
positioned at bottom
End View
Max wall thickness
335 mm
Model Concentric Flue Diameter
22-60 Cover (100mm) 150mm 75-115 Cover (130mm) 200mm
- Type C12 C32 & C62 Appliances
Page 18
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
12
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.
7.2 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 than 4.7 m
3
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 cm
2
per kW of rated heat input above 70 kW
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 accordance with
Section 7.2.1 and local and national
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.
Figure 7: Heaters Installed in Isolated Equipment Rooms
Wall
Outside
Wall
High Level Ventilation
Low Level Ventilation
Max Temperature 32° C Room Air Pressure Must Not be Negative.
Duct Distribution System or Discharge to Heated Space
Return Air Duct
from Heated
Space or Fresh
Air from Outside
Flue
Air Intake
Manifold
Page 19
SECTION 8: OPTIONAL HEATER CONFIGURATIONS
13
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
on Page 6, Section 4.2 and in the correct direction across the heat exchanger as indicated by the arrow on the heater. Higher air flows are permitted, but will cause a lower exiting air temperature. It is recommended that the fan is positioned to blow the air through the heat exchanger.
The duct must be designed as described on Page 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.
Figure 8: Ducting
Ducting
Dimension
X
Minimum-
Twice
Dimension
X
Minimum-
Twice
Dimension
X
Airflow Indicator
Flexible Flange
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.
Page 20
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
14
SECTION 9: GAS PIPING
WARNING
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.
It is important that the gas supply pipe and the electrical connections do not support any of the 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 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.
9.1 Connections
Connect the heater to the gas supply ensuring that the final connections are as follows:
• Gas supply pipe work is run in medium or heavy gauge tubing in compliance with local and national codes.
• The gas supply pipe is adequately sized to carry the total volume of gas for the complete 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
one pipe size larger than the heater gas connection.
IMPORTANT - The complete installation must be purged and tested for gas soundness in accordance with local and national codes.
Figure 9: Gas Connection with Stainless Steel Flex Connector
Gas Isolating Valve
Drip Leg
Cap
Union
Connection
Option B:
Medium or Heavy Gauge Tubing Gas Connector
Option A:
Stainless Steel Flex Gas 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.
Page 21
SECTION 10: WIRING AND ELECTRICAL INFORMATION
15
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.
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 block on the inside of the heater using 1 mm
2
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.
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.
See Page 16,
Section 10.3. through Page 17, Section 10.4.
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.
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.
Page 22
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
16
10.3 CTUA Wiring Diagram (Models 22-60)
IGNITION MODULE
BLACK
Plug in Connection to Gas Valve
S4565C 1017 Control
Honeywell
BLACK
SENSE
IGNITION
230 V
1 Ø
50 Hz
IGNITION MODULE
LOCKOUT
GAS VALVE
RUN
1112 7910 8 564
SITE WIRING
23 1
E
N L 1 2 3 7 8
BLUE
BROWN
BLUE
MAINS FILTER
Pressure Switch
Detail
WHITE
YELLOW
BLACK
Thermostat Limit
Thermodisc N/C
BROWN
BROWN
RED
RED
AXIAL FAN
COMBUSTION
FAN
N L
E
N L
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
THERMOSTAT
REMOTE FAN ON
LINE
NEUTRAL
GROUND
YELLOW
BLACK
WHITE
PRESSURE SWITCH
GREEN/YELLOW
BLACK
BROWN
BROWN
BROWN
YELLOW
BLUE
WHITE
PINK
PURPLE
GREY
NO\P(3)
C\P(1)
NC\P(2)
GREEN/YELLOW
BLUE
BROWN
BLUE
BROWN
Time Delay Relay
LOCKOUT
RESET
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.
Page 23
SECTION 10: WIRING AND ELECTRICAL INFORMATION
17
10.4 CTUA Wiring Diagram (Models 75-115)
S 4563 C Honeywell
230 V
1 Ø
50 Hz
SITE WIRING
N L 1 2 3 7 8
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
THERMOSTAT
REMOTE FAN ON
LINE
NEUTRAL
GROUND
L
N
E
COMBUSTION FAN
AXIAL FAN
L
N
E
BROWN
RED
NC\P(2)
Pressure Switch
Detail
NO\P(3)
C \P(1)
BLACK
YELLOW
WHITE
PRESSURE SWITCH
AXIAL FAN
BLUE
PINK
GREY
PURPLE
LOCKOUT
RUN
GREEN/YELLOW
BLACK
WHITE
YELLOW
GREEN/YELLOW
BROWN
BLUE
BROWN
BLUE
BLUE
BROWN
MAINS FILTER
GREEN/YELLOW
BLACK
SENSE
IGNITION
BLACK
BROWN
BLUE
L
N
E
Thermostat Limit
Thermodisc N/C
BROWN
Time Delay Relay
BLUE
BROWN
BROWN
LOCKOUT
RESET
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.
Page 24
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
18
10.5 CTUB/C Wiring Diagram (Models 22-40)
IGNITION MODULE
BLACK
Plug in Connection to Gas Valve
S4565C 1017 Control
Honeywell
BLACK
SENSE
IGNITION
230 V
1 Ø
50 Hz
IGNITION MODULE
LOCKOUT
GAS VALVE
RUN
1112 7910 8 564
SITE WIRING
23 1
N L 1 2 3 7 8
BLUE
BROWN
BLUE
MAINS FILTER
Pressure Switch
Detail
WHITE
YELLOW
BLACK
BROWN
RED
RED
COMBUSTION
FAN
E
N L
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
THERMOSTAT
REMOTE FAN ON
LINE
NEUTRAL
GROUND
YELLOW
BLACK
WHITE
PRESSURE SWITCH
GREEN/YELLOW
NO\P(3)
C\P(1)
NC\P(2)
GREEN/YELLOW
WHITE N
LOW RED
CENTRIFUGAL
FAN
HIGH BLACK
MEDIUM BLUE
Thermostat Limit
Thermodisc N/C
BROWN
BLUE
BROWN
Time Delay Relay
BLACK
BROWN
BROWN
BROWN
YELLOW
BLUE
WHITE
PINK
PURPLE
GREY
LOCKOUT
RESET
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.
Page 25
SECTION 10: WIRING AND ELECTRICAL INFORMATION
19
10.6 CTUB/C Wiring Diagram (Models 50-60)
B
7
8
9
A
5
4
6
RELAY
IGNITION MODULE
BLACK
Plug in Connection to Gas Valve
S4565C 1017 Control
Honeywell
BLACK
SENSE
IGNITION
230 V
1 Ø
50 Hz
IGNITION MODULE
LOCKOUT
GAS VALVE
RUN
1112 7910 8 564
SITE WIRING
23 1
N L 1 2 3 7 8
BLUE
BROWN
BLUE
MAINS FILTER
Pressure Switch
Detail
WHITE
YELLOW
BLACK
BROWN
RED
RED
E
N L
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
THERMOSTAT
REMOTE FAN ON
LINE
NEUTRAL
GROUND
YELLOW
BLACK
WHITE
PRESSURE SWITCH
GREEN/YELLOW
BLACK
BROWN
BROWN
BROWN
YELLOW
BLUE
WHITE
PINK
PURPLE
GREY
NO\P(3)
C\P(1)
NC\P(2)
GREEN/YELLOW
WHITE N
LOW RED
HIGH BLACK
MEDIUM BLUE
CENTRIFUGAL FAN 2
CENTRIFUGAL FAN 1
GREEN/YELLOW
WHITE N
LOW RED
HIGH BLACK
MEDIUM BLUE
COMBUSTION
FAN
Thermostat Limit
Thermodisc N/C
BROWN
BLUE
BROWN
Time Delay Relay
LOCKOUT
RESET
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.
Page 26
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
20
10.7 CTUB/C Wiring Diagram (Models 75-115)
S 4563 C Honeywell
MEDIUM BLUE
L
N
E
A
B
4
5
6
7
8
9
COMBUSTION FAN
BROWN
RED
NC\P(2)
Pressure Switch
Detail
NO\P(3)
C \P(1)
BLACK
YELLOW
WHITE
PRESSURE SWITCH
BLUE
PINK
GREY
PURPLE
LOCKOUT
RUN
GREEN/YELLOW
BLACK
WHITE
YELLOW
GREEN/YELLOW
BROWN
BLUE
BROWN
BLUE
MAINS FILTER
BLACK
SENSE
IGNITION
BLACK
BROWN
BLUE
SITE WIRING
N L 1 2 3 7 8
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
THERMOSTAT
REMOTE FAN ON
LINE
NEUTRAL
GROUND
230 V
1 Ø
50 Hz
CENTRIFUGAL FAN 1
CENTRIFUGAL FAN 2
MEDIUM BLUE
LOW RED
RELAY
GREEN/YELLOW
WHITE N
HIGH BLACK
LOW RED
HIGH BLACK
WHITE N
GREEN/YELLOW
MEDIUM BLUE
LOW RED
GREEN/YELLOW
WHITE N
HIGH BLACK
CENTRIFUGAL FAN 3
models 100-115 only
Thermostat Limit
Thermodisc N/C
BROWN
Time Delay Relay
BLUE
BROWN
BROWN
LOCKOUT
RESET
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.
Page 27
SECTION 10: WIRING AND ELECTRICAL INFORMATION
21
10.8 CTUD Wiring Diagram (Models 22-60)
IGNITION MODULE
BLACK
Plug in Connection to Gas Valve
S4565C 1017 Control
Honeywell
BLACK
SENSE
IGNITION
230 V
1 Ø
50 Hz
IGNITION MODULE
LOCKOUT
GAS VALVE
RUN
1112 7910 8 564
SITE WIRING
23 1
N L 1 2 3 7 8
BLUE
BROWN
BLUE
MAINS FILTER
Pressure Switch
Detail
WHITE
YELLOW
BLACK
BROWN
COMBUSTION
FAN
E
N L
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
THERMOSTAT
LINE
NEUTRAL
GROUND
YELLOW
BLACK
WHITE
PRESSURE SWITCH
GREEN/YELLOW
BLACK
BROWN
BROWN
BROWN
YELLOW
BLUE
WHITE
PINK
PURPLE
GREY
NO\P(3)
C\P(1)
NC\P(2)
RED
RED
Thermostat Limit
Thermodisc N/C
BROWN
BLUE
BROWN
Time Delay Relay
LOCKOUT
RESET
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.
Page 28
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
22
10.9 CTUD Wiring Diagram (Models 75-115)
S 4563 C Honeywell
L
N
E
COMBUSTION FAN
NC\P(2)
Pressure Switch
Detail
NO\P(3)
C \P(1)
BLACK
YELLOW
WHITE
PRESSURE SWITCH
BLUE
PINK
GREY
PURPLE
LOCKOUT
RUN
GREEN/YELLOW
BLACK
WHITE
YELLOW
GREEN/YELLOW
BROWN
BLUE
BROWN
BLUE
MAINS FILTER
BLACK
SENSE
IGNITION
BLACK
BROWN
BLUE
SITE WIRING
N L 1 2 3 7 8
REMOTE LOCKOUT RESET
REMOTE LOCKOUT INDICATION
THERMOSTAT
LINE
NEUTRAL
GROUND
230 V
1 Ø
50 Hz
BROWN
RED
Thermostat Limit
Thermodisc N/C
BROWN
Time Delay Relay
BLUE
BROWN
BROWN
LOCKOUT
RESET
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.
Page 29
SECTION 10: WIRING AND ELECTRICAL INFORMATION
23
10.10 CTUD External Motor Alternative Wiring
2A
230v
LLL
1
2
3
N
400 V 3 Ø motor
Three Phase Motor
400 V 50 Hz
3 Ø Supply
NL 1 2 3
Contactor or Relay
Overload protection must be provided at the motor or contactor.
Room
Thermostat
Frost
Thermostat
230 V 50 Hz Time Switch
RDW 1565
be provided at the motor
NL 1 2 3
2A
230 V
Contactor or Relay
Single Phase Motor with Load over 7 Amps
N
L
Overload protection must
or contactor.
230 V 50 Hz
supply
Single Phase Motor with Load Over 7 Amps
Room
Thermostat
Frost
Thermostat
230 V 50 Hz Time Switch
& Optional Thermostat/Time Switch
Page 30
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
24
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
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
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.
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.
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
on Page 25, Figure 10. There will be no ignition of the burner and lockout will occur, which proves the controls are operating correctly.
Page 31
SECTION 11: COMMISSIONING
25
Figure 10: Automatic Burner Control Box Sequence
Burner sequence for Honeywell S4563 or S4565C
Flame Signal
Start Gas Valve
Ignition Spark
Supply 230 V
CLOSE DOWNRUNSTART
ts**
Signals Output By Control
Flue Fan
Pressure Switch
P
C
NO
NC
30 Sec. Purge*
*Purge time begins at pressure switch change over. **ts=Safety time (S4563C=3 seconds [alternate 5 seconds]; S4565C=5 seconds)
Required Incoming Signals
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)
Regulator
(Under Cover)
Inlet Pressure
Gas Inlet
Ignition Control (Plugs into Gas Valve)
12 Cable Connector
Outlet Pressure
Fixing Screw
Ignition
Output
Flame Probe
Connection
End View
Page 32
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
26
Figure 12: Gas Valve for Heater (Models 75 - 115)
Regulator
(Under Cover)
Inlet Pressure
Gas Outlet
Outlet Pressure
Plug for
Main Gas Valve
Gas Inlet
Plug for
Main Safety
Gas Valve
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.
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.
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
2
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.
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
SECTION 11: COMMISSIONING
27
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.
Page 34
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
28
SECTION 12: USER INSTRUCTIONS
12.1 User Instructions
The CTU heaters are fully automatic and operate from the external controls fitted on site.
The only user controls at the heater are the: Burner Lockout Reset Button:
See Page 28, Section 12.3.2
Thermostat Limit Thermodisc Reset Button:
See Page 28, Section 12.3.1
WARNING
Electrical Shock Hazard
Disconnect electrical power before servicing.
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
ON
RUN ON
CLOSE DOWN
THERMOSTAT
CALL FOR
HEAT
BURNER
RUN
FAN
2-3 MINUTES
ON
ON
12.3 Common User Controls
12.3.1 Thermostat Limit Thermodisc
Press to reset
These are hand reset devices to give further protection against fan failure.
NOTE: To reset, the heat exchanger must be cool.
Description Part Number
All Models 90412100
WARNING
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.
Page 35
SECTION 12: USER INSTRUCTIONS
29
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.
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.
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. Leave the building.
6. Immediately call your local gas supplier after leaving the building. Follow the gas suppliers instructions.
7. If you cannot reach your gas supplier, call the Fire Department.
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.
Page 36
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
30
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 heater must be done by a contractor qualified in the installation and service of gas-fired heating
equipment.
WARNING
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.
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 heater to operate. Minor faults may be traced by using the troubleshooting charts
on Page 32,
Section 15 through Page 34, Section 15.4.
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.
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.
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.
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 be found
on Page 41, Section 16.9 and the standard 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 setting on the heater without prior consultation with Roberts-Gordon.
The "HIGH" speed option is available to give the normal required air flow against higher static pressures and is not intended to be operated free blowing or against low resistance. Use of the fans under these conditions may cause the fan thermal overload to operate and the fan thermostat to cycle.
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.
See
Page 40, Section 16.8.2.
13.4 Heat Exchanger Maintenance
The heat exchanger will remain clean unless a problem has developed with combustion. Inspect the heat exchanger. Look for signs of overheating at the front tubes which may indicate burner over firing or persistently low air flows.
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
31
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.
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.
Page 38
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
32
SECTION 15: TROUBLESHOOTING
15.1 General
If problems persist, contact
ROBERTS GORDON
®
at
Tel: +44(0)121 506 7709
www.rg-inc.com
Heater Operating
TROUBLESHOOT ENDS.
No
Check for mis-wiring.
Change time delay relay.
Check time delat relay. Is
there 230 V accross brown
and blue wires?
Ye s
No
No
Ye s
Check limt thermostat(s);
Reset.
No
No
Use 15.2 to test burner.
Ye s
Ye s
Use 15.2 to test burner.
Is Red lockout
warning light on?
Ye s
No
Turn on supplies.
Are gas & electrical
supplies on?
No
Ye s
Start
With external controls on, does the burner continue
to fire?
Is distribution air fan
operating?
WARNING
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.
For your safety and optimum heater performance, use only ROBERTS GORDON® replacement parts.
Conduct Commissioning procedure as shown on Page 24, Section 11.
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 Roberts­Gordon and conform to all requirements set forth in the
ROBERTS GORDON® manuals and all
applicable governmental authorities pertaining to the installation, service and operation of the equipment. To help facilitate optimum performance and safety, Roberts-Gordon recommends that a qualified contractor annually inspect your
ROBERTS
GORDON
®
equipment and perform service
where necessary, using only replacement parts sold and supplied by Roberts-Gordon.
Page 39
SECTION 15: TROUBLESHOOTING
33
15.2 Troubleshooting For Automatic Ignition Burner Systems
Heater Operating
TROUBLESHOOT ENDS.
No
Trace fault in supervision
system. See Section 16.3.
No
Ye s
Is red lockout light on?
No
Is the flame current at
least 1 µAmp DC when
the flame lights?
Ignition control faulty
replace.
See Section 15.6.
Is HT lead okay and
connected?
Is spark electrode okay?
Ye s
Replace valve.
Is the gas valve operating?
To test valve,
see Section 15.4.
No
Does the flame light?
No
Ye s
Wait 30 - 40 seconds.
Is ignition spark operating?
No
Ye s
Flue fan faulty replace
Burner control faulty or plug in connections faulty. Repair
or replace as necessary
Check for too much flue/air inlet
duct. Check for blockage in
combustion air circuit.
Check for faulty air pressure
switch. See section 16.5.
Does air pressure switch
change over?
No
Ye s
Has the thermostat limit
thermodisc operated or light
faulty? Reset or replace as
necessary.
Is 230 V supply at fan
connections?
Does flue fan run?
No
Are external controls on?
Ye s
Ye s
Is the green light on?
No
Ye s
Is red lockout light on?
No
Ye s
Press in lockout reset button
on rear of heater or remote
reset button if fitted.
Turn on supplies.
Are gas & electrical
supplies on?
Ye s
Start
No
Ye s
No
If problems persist, contact
ROBERTS GORDON
®
at
Tel: +44(0) 121 506 7709
www.rg-inc.com
WARNING
Electrical Shock Hazard
Do not touch ignition components.
Voltage from ignition components is high.
Failure to follow these instructions can result in death or electrical shock.
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.
For your safety and optimum heater performance, use only ROBERTS GORDON
®
replacement parts.
Conduct Commissioning procedure as shown on Page 24, Section 11.
Page 40
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
34
15.3 Troubleshooting for Flame Supervision System
Repair or replace as
necessary.
Control box faulty.
Replace with correct type.
Use section 15.1 to
trace the fault.
Heater Operating
TROUBLESHOOT ENDS.
No
Repair or replace as
necessary.
Is inlet burner gas pressure
correct? Is live and neutral
polarity correct? Is
flame probe circuit correct?
Is there a current flowing in the
flame probe circuit with no
flame present?
Ye s
No
Does lockout occur when
there is a flame present?
Ye s
Is the connecting lead damaged? Is the flame probe damaged or touching earthed
components?
No
Is the green light on and
at least 1 µA DC flame
current?
Connect a DC ammeter in
series with the flame probe.
Ye s
No
Ye s
Ye s
No
START
If problems persist, contact
ROBERTS GORDON
®
at
Tel: +44(0) 121 506 7709
www.rg-inc.com
NOTE: Minimum flame probe current 1 μA DC. Typical flame probe current 3-5 μA DC.
15.4 Troubleshooting for Solenoid Valves
Valve faulty.
Replace with one of
correct type.
Fault elsewhere
Fault elsewhere
Valve Operating
TROUBLESHOOT ENDS.
No
Ye s
Valve faulty.
Replace with one of
correct type.
Does gas pressure at
outlet of valve return to zero or
lower when valve turns off?
No
Ye s
Does gas pressure at outlet
of the valve rise when
valve turns on?
No
Ye s
Is gas pressure at inlet of the
valve correct for gas type?
Note pressure found.
No
Ye s
START
Is 230 V at the valve
terminals at the
appropriate time.
Ye s
No
If problems persist, contact
ROBERTS GORDON
®
at
Tel: +44(0) 121 506 7709
www.rg-inc.com
Page 41
SECTION 16: REMOVAL AND REPLACEMENT PARTS
35
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
Disconnect wire harness
Unplug control from valve
Remove fixing screw
Ignition Control
Description Part Number
Gas Valve VR4105A 90033403 Ignition Control 90434010
Models 22 - 60
16.1.2
Step 1
Unscrew
gas pipe from the
valve inlet.
Step 2
Unscrew valve from the
burner manifold
or
unscrew the fixing screws for
the inlet and outlet flanges.
Unplug
electrical lead.
(rectifier harness)
Ignition Control
Description Part Number
Gas Valve VR4605 90033404 Ignition Control 90434020
Models 75 - 115
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
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.
Page 42
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
36
16.2 Burner Compartment
Remove flexible
air duct from spigot
Remove
access plate
Remove screws and
pull off burner cover
Viewing port
for flame probe
Viewing port
for ignition electrode
Flame probe
Burner
compartment
cover
Rubber Seal
Ignition electrode
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
Remove manifold
screws and pull
out manifold
Manifold
Burners
Injectors
Burner
Screws
Burner venturi
Unscrew
Injectors
Manifold
Marking
Ensure gas tight fitting of injectors. Ensure correct alignment with burners. Ensure all pipe joints are gas tight.
Burner Injectors
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
in Ø 0.0492 0.0551 0.0551 0.0551 0.0551 0.0531 0.0594 0.0594 0.0594 0.0594
Marking 125 54 54 54 54 135 53 53 53 53
RG P/N 91930125 91930054 91930054 91930054 91930054 91930135 91930053 91930053 91930053 91930053
Page 43
SECTION 16: REMOVAL AND REPLACEMENT PARTS
37
16.3 Ignition Electrode and Flame Probe
Description Part Number
Spark Electrode 90427411 Automatic Ignition Flame Probe 90439300 Burners (all models except CTU-40) 92000000 Burners - CTU-40 92000001
Flame
Probe
Ignition
Electrode
Remove
Screw
Ignition
Electrode
Burners
Flame
Probe
Burners
Burner Compartment
Front Views
Remove all
burner compartment
screws to remove
the burner
compartment and
access the
Front View.
Thermostat
Limit
Thermodisc
.120
(3 mm)
spark
gap
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.
Page 44
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
38
16.4 Flue Fan
Vent Box
Outlet Gasket
Flue Fan
Vent Box
Screws
Flue
Adapter
Flue Adapter
to Flue Fan
screws
Rear Panel
Hole
Disconnect
electrical connections
at plug in tabs.
Mounting Plate
to Vent Box
Screws
Mounting
Plate
Gasket
Air Plate
Mounting Plate
to Flue Fan
Screws
Vent Box
Gasket
Remove screws securing outlet flange to the flue adapter.
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 DS A
508-128 077272
To r i n D SA
508-128
077272
Tor in DSA
508-128
077272
Tor in DSA
508-128
077272
To r i n D SA
524-202
077273
Tor in DSA
524-202
077273
AO Smith
JFIG098NS
AO Smith
JFIG098NS
AO Smith
JFIG098NS
To r i n D S F
146-052
077274
RG P/N 90710430 90710430 90710430 90710430 90710440 90710440 90710001 90710001 90710001 90710450
Air mm Ø
Plate in Ø
47.6
1.875
53.1
2.09
60.7
2.39
69.1
2.72
60.7
2.39
69.9
2.75
97.0
3.82
103 .6
4.08
110 . 5
4.35
152.4 6
RG P/N 11 01113 9 11 0113 8 110 114 0 110111 3 7 11 01113 6 110111 35 110111 34 11 01113 3 110 1113 2 11 01113 1
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.
Page 45
SECTION 16: REMOVAL AND REPLACEMENT PARTS
39
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.
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.
WARNING
Carry out a commission after working on or changing a pressure switch.
See Page 24, Section
11 .
Pressure
Switch
CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115
RG P/N 90439801 90439810 90439804 90439803 90439810 90439802 90439811 90439807 90439811 90439807
Colour
Code
pink grey white grey grey yellow grey brown grey brown
Set Point
mbar
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
in wc 0.23 0.37 0.47 0.41 0.35 0.32 0.72 0.68 0.72 0.68
Page 46
COMBAT® CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL
40
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.
16.7.1 Fan Removal
Remove the four screws
and rubber washers.
Description Part Number
Axial Fan 16 in. 90710418 Axial Fan 500 mm. 90710419
and Replacement
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.
• 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.
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.
Page 47
SECTION 16: REMOVAL AND REPLACEMENT PARTS
41
• 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.
• Set all fans to operate at the same speed.
Figure 14: Centrifugal Fan Orientation
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
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
RG P/N
90710418 90710418 90710418 90710419 90710419 90710418 90710418 90710419 90710419
Quantity 1 1 1 1 1 2 2 2 2
Fan Ratin g
(Watts per Fan)
160 160 160 370 370 160 160 370 370
Centrifugal Fan Type
CTUB/C Models
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
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 12 00
High Fan Rating (W) 1400 1400 1400 1400 1400 1700 1700 1700 1700
Page 48
Page 49
Page 50
Page 51
WARNING
© 2007 Roberts-Gordon, LLC www.rg-inc.com Printed in U.S.A. P/N 91040028 Rev B
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).
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.
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.
IF THE HEATER WILL NOT OPERATE, TO ENSURE YOUR SAFETY,
FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER
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.
TO TURN OFF THE HEATER
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
Roberts-Gordon, LLC
1250 William Street P.O. Box 44 Buffalo, NY 14240-0044 USA
Roberts-Gordon Europe Limited
Unit A, Kings Hill Business Park Darlaston Road, Wednesbury West Midlands WS10 7SH UK Telephone: +44(0)121 506 7700
®
50 cm
50 cm**
30 cm
15 cm
Clearances to Combustibles
15 cm
2.5 - 3.5 m*
3 m
60 cm
Wall
Terminal
Roof Terminal
Air
Intake
Flue
Installation Clearances
**80 cm is necessary to service heater.
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
®
manuals and all applicable governmental authorities pertaining to the installation, service and operation of the equipment. To help
facilitate optimum performance and safety, Roberts-Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON
®
equipment and perform service where necessary,
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.
Telephone: 716.852.4400 Fax: 716.852.0854 Toll Free: 800.828.7450
*Heaters may be mounted at a higher level if destratification fans and/or turn down nozzles are installed.
SECTION 16: REMOVAL AND REPLACEMENT PARTS
45
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