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.
®
C mbat
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.
Compact Tubular Unit Heaters
Installation, Commissioning,
Operation & Service Manual
WARNING
Models CTCU 7
CTCU 11
CTCU 15
CTCU 22
CTCU 27
CTCU 32
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.
Installer
WARNING
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.
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.
Owner
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Installation must be done by a registered installer/
contractor qualified in the installation and service
of gas-fired heating equipment or your gas supplier.
Roberts-Gordon Europe Limited
Oxford Street
Bilston, West Midlands WV14 7EG UK
Telephone: +44(0) 1902 494425
Fax: +44(0) 1902 403200
Service Telephone: +44(0) 1902 498733
Service Fax: +44(0) 1902 401464
E-mail: [email protected]
E-mail: [email protected]
Quality in Any Language™
© Copyright 2006 Roberts-Gordon, LLC
P/N 111100UK Rev B 10/06
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TABLE OF CONTENTS
SECTION 1: Heater Safety......................................................2 SECTION 13: Conversion Between Gases..........................21
SECTION 2: Installer Responsibility .....................................2
2.1 Clearances to Combustibles........................................2
2.2 Corrosive Chemicals....................................................2
13.1 General ....................................................................21
13.2 Burner Conversion ...................................................21
13.3 Gas Valves ...............................................................21
2.3 National Standards and Applicable Codes ..................2 SECTION 14: Troubleshooting .............................................22
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
14.1 General ....................................................................22
14.2 Troubleshooting For Automatic Ignition
Burner Systems .......................................................23
14.3 Troubleshooting for Flame Supervision System .......24
14.4 Troubleshooting for Solenoid Valves ........................25
14.5 Troubleshooting for Main Fan...................................25
3.6 Gas Supply..................................................................3 SECTION 15: Removal and Replacement Parts..................26
3.7 Electrical Supply..........................................................3
3.8 Flue..............................................................................3
SECTION 4: Specifications ....................................................5
4.1 CTCUA (All Models) ....................................................5
4.2 General Technical Data Table (All Models)..................6
4.3 Technical Data Table (All Models)................................6
SECTION 5: Heater Installation..............................................7
5.1 General........................................................................7
5.2 Shelf Mounting and Suspension..................................7
5.3 Wall Mounting..............................................................7
SECTION 6: Flue Installation .................................................9
6.1 Changing Flue and Air Intake Orientation....................9
6.2 Flue Installation............................................................9
6.3 Type C12, C32 & C62 Appliance......................................9
6.4 Type B22 Appliance.......................................................9
SECTION 7: Air Supply......................................................... 11
7.1 Room Sealed Installation ........................................... 11
7.2 Open Flued Installation .............................................. 11
7.3 Building Ventilation..................................................... 11
SECTION 8: Gas Piping........................................................ 12
8.1 Connections............................................................... 12
SECTION 9: Wiring and Electrical Information................... 13
9.1 Electrical Supply........................................................ 13
9.2 Remote Controls........................................................ 13
9.3 CTCUA Wiring Diagram Models 7 - 32...................... 14
SECTION 10: Commissioning.............................................. 15
10.1 Pre-Commission Checks.......................................... 15
10.2 Begin Commissioning .............................................. 15
10.3 Complete the Commissioning.................................. 17
SECTION 11: User Instructions............................................ 18
11.1 User Instructions....................................................... 18
11.2 Heater Operation ...................................................... 18
11.3 Common User Controls ............................................ 18
11.4 Lighting Instructions.................................................. 18
11.5 Simple Fault Finding ................................................. 19
SECTION 12: Servicing.........................................................20
12.1 Servicing Instructions ..............................................20
12.2 Burner Maintenance ................................................20
12.3 Fan/Motor Assembly Maintenance...........................20
12.4 Heat Exchanger Maintenance..................................20
12.5 Gas Control Valve Maintenance...............................20
12.6 Flue Fan...................................................................20
15.1 Gas Valve.................................................................26
15.2 Burner Compartment ...............................................27
15.3 Ignition Electrode and Flame Probe.........................28
15.4 Flue Fan Vertical Installation....................................29
15.5 Pressure Switch........................................................30
15.6 Ignition Control.........................................................31
15.7 CTCUA Axial Fan/Guard/Motor Assembly ...............31
15.8 Fan and Limit Thermostats ......................................31
© 2006 Roberts-Gordon, LLC
All rights reserved. No part of this work covered by the copyrights herein may be reproduced
or copied in any form or by any means - graphic, electronic, or mechanical, including
photocopying, recording, taping or information storage and retrieval systems - without the
written permission of Roberts-Gordon, LLC.
Printed in U.S.A.
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TABLE OF FIGURES
Figure 1: Installation Clearances and Clearances to
Combustibles..............................................................4
Figure 2: Suspension Methods .................................................7
Figure 3: Shelf Mounting and Hanging Suspension..................8
Figure 4: Vertical Louvres (Optional) ........................................8
Figure 5: Flue and Roof Detail ..................................................9
Figure 6: Vertical and Horizontal Flue Termination -
Type B22 Appliance................................................... 10
Figure 7: Vertical and Horizontal Flue Termination -
Type C12 C32 & C62 Appliances.................................. 10
Figure 8: Gas Connection with Stainless Steel
Flex Connector......................................................... 12
Figure 9: Automatic Burner Control Box Sequence ................ 16
Figure 10: Gas Valve for Heater Models 7 - 32 ....................... 16
Figure 11: Heater Operating Sequence................................... 18
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COMBAT® Compact Tubular Unit Heaters are high efficiency heaters and are listed on
the Enhanced Capital Allowance Scheme ’Energy Technology Product List.’ The ETL
symbol is a UK registered certification mark of The Carbon Trust.
Product Approval
ROBERTS GORDON® appliances have been tested and CE certified as complying with the essential
requirements of the Gas Appliance Directive, the Low Voltage Directive, the Electromagnetic
Compatibility Directive and the Machinery Directive for use on natural gas and LPG when installed,
commissioned and maintained in accordance with these instructions.
These instructions refer to appliances designed to operate in the European Union.
Appliances designed for other countries (non European Union) are available on request.
This appliance must be installed in accordance with the local and national codes in force and used
only in a sufficiently ventilated space, as specified in these instructions.
Before installation, check that the local gas distribution systems, nature of gas and pressure, and
adjustment of the appliance are compatible.
1
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 1: HEATER SAFETY
Your Safety is Important to Us!
clearances to combustibles. Affix the tag on a wall
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.
near the heater.
2.2 Corrosive Chemicals
CAUTION
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.
Read this manual carefully before installation,
operation, or service of this equipment.
Failure to follow these instructions can result in
property damage.
This heater is designed for heating non-residential
indoor spaces. Do not install in residential spaces.
These instructions, the layout drawing, local codes
and ordinances and applicable standards that apply
to gas piping, electrical wiring, venting, etc. must be
thoroughly understood before proceeding with the
installation.
Roberts-Gordon cannot be responsible for ensuring
that all appropriate safety measures are undertaken
prior to installation; this is entirely the responsibility
of the installer. It is essential that the contractor, the
sub-contractor, or the owner identifies the presence
of combustible materials, corrosive chemicals or
halogenated hydrocarbons* anywhere in the
premises.
SECTION 2: INSTALLER RESPONSIBILITY
• To install the heater, as well as the gas and elec-
trical supplies, in accordance with applicable
specifications and codes. Roberts-Gordon
recommends the installer contact a local
building inspector, Fire Officer or insurance
company for guidance.
* Halogenated Hydrocarbons are a family of chemical
compounds characterized by the presence of halogen
elements (fluorine, chlorine, bromine, etc.). These
compounds are frequently used in refrigerants, cleaning
agents, solvents, etc. If these compounds enter the air
supply of the burner, the lifespan of the heater
components will be greatly reduced. Warranty will be
invalid if the heater is exposed to halogenated
hydrocarbons.
• To use the information given in the manual
together with the local and national codes to
perform the installation.
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.
• 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 is on the back cover of
this manual as a permanent reminder of the safety
instructions and the importance of the required
2
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SECTION 3: CRITICAL CONSIDERATIONS
SECTION 3: CRITICAL CONSIDERATIONS
3.1 Basic Information
3.8 Flue
CTCU heaters have automatic ignition burners for
ON/OFF operation only.
Choose heater siting to allow for the proper location
of the flue. Each heater must be fitted with an
individual and correctly sized sealed flue system
(See Page 9, Section 6).
3.2 Location and Suspension
All models:
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.
• Must be installed indoors.
• Must be installed in a level position with horizon-
tal or vertical discharge.
• May be mounted on a shelf of non-combustible
material. (See Page 5, Section 4 and Page 7,
Figure 2 for support points.)
• May be suspended from above (See Page 7, Fig-
ure 2) or from wall brackets of sufficient strength
to support the heater as listed in the Dimension
Data Table on Page 5, Section 4.1. Drop rods
must be a minimum of 10 mm diameter mild
steel. Four suspension points (M10 nuts) are
located on top and back side of the heater.
• Must be installed in a manner which allows
access to all serviceable components.
3.3 Minimum Required Installation Clearances
Clearances around the heater and flue must be as
indicated on Page 4, Figure 1; Page 9, Figure 5
through Page 10, Figure 7 to ensure access for
servicing, and correct operation.
3.4 Clearances to Combustibles
Clearances must be as indicated on Page 4, Figure
1. If clearances to combustibles are not indicated,
then installation clearances apply.
3.5 Ventilation
It is important to ensure that there is adequate air
circulation around the heater to supply air for
combustion, ventilation and distribution in
accordance with local and national codes.
3.6 Gas Supply
It is important that the gas supply pipe is sized
correctly to provide the inlet pressure as stated on
the heater data plate. The gas supply pipe and
electrical connections must not support any of the
heater's weight.
3.7 Electrical Supply
A permanent 230 V 50 Hz 1 Ø electrical supply is
required at the main electrical terminals. The heater
also requires suitable energy controls in accordance
with Section 9.
3
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
WARNING
Fire Hazard
Some objects will catch fire or explode when placed
close to heater.
Keep all flammable objects, liquids and vapours the
required distance away from the heater.
Failure to follow these instructions can result in death,
injury or property damage.
Figure 1: Installation Clearances and Clearances to Combustibles
Installation Clearances
Roof Terminal
Clearances to Combustibles
Roof Terminal
15 cm
Air
15 cm
3 m
Intake
50 cm**
10 cm
Flue
Wall
Terminal
25 cm
30 cm
3 m
2.5 - 3.5 m*
* Heaters may be mounted at a higher level if destratification
fans are installed.
**80 cm is necessary to service
heater.
The heater must always be installed at least 1.8 m above the floor.
The flue pipe must have clearance from combustibles by 5 cm.
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
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SECTION 4: SPECIFICATIONS
SECTION 4: SPECIFICATIONS
4.1 CTCUA (All Models)
Top View
14
448
265
4 x M10 Captive Nuts Provided
Air Intake
(Optional Position)
422
463
Flue
120
(Optional Position)
Mounting
Holes
C
171
Rear View
End View
4 x M10 Captive Nuts Provided
448
660
Air Intake
on Model 22
514
Flue
D
171
120
*
B
A
Air Intake
Electrical
Mounting
Holes
Connection
Lockout Reset
Gas Supply
45
85
728
* 140 for 27 - 32
Dimension Data - CTCUA (All Models)
Model
CTCU-7
CTCU-11
CTCU-15
CTCU-22
CTCU-27 / 32
mm
304
304
450
450
578
Height
A
B
C
D
(in)
(12.0)
(12.0)
(17.7)
(17.7)
(22.8)
mm
(in)
mm
(in)
mm
(in)
513
(20.2)
149
(5.9)
59
(2.3)
239
(9.4)
151
(5.9)
68
(2.7)
239
(9.4)
151
(5.9)
68
(2.7)
385
(15.2)
151
(5.9)
68
(2.7)
385
(15.2)
172
(6.8)
46
(1.8)
Mounting Hole Spacing
Centre of Flue (Top Option)
Centre of Flue
Weight
kg
28
30.5
38.5
41
52.3
5
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
4.2 General Technical Data Table (All Models)
Model
CTCU-7
CTCU-11
CTCU-15
CTCU-22
CTCU-27 / 32
CTCUA, Axial Fans
Total Electrical Load
Run Current
W
A
260
1.1
274
1.2
336
1.5
384
1.7
345
1.5
Start Current
A
1.7
1.8
2.5
2.9
2.6
Air Flow
m3/h
1120
1220
2710
2750
4474
[NR]
dB(A)
[31]
37
[35]
41
[39]
45
[42]
48
[42]
48
Sound Pressure Level at 3 m
Flue and AIr Intake
Flue and Air Intake Size
mm Ø
m
80
80
4
80
5
80
5
100
5
*Maximum Straight Flue/Air Intake
2.5
Electrical load at 230 V 50 Hz measured by calculating from total run current of appliance.
* Do not exceed the maximum length of flue stated or heater may not operate properly.
Reduce the maximum length stated by 1 m for each 90° bend installed.
**If minimum air flow requirements are not met, then temperature limit devices will shut down the heater.
4.3 Technical Data Table (All Models)
Appliance Category II 2H/L 3B/P
Model
CTCU-7 CTCU-11 CTCU-15 CTCU-22 CTCU-27 CTCU-32
Heat Input
Gross CV
kW
8.5
29
13.4
46
18.3
62
27.5
94
33
113
38.5
131
(Btu/h) x (1000)
Heat Input
Net CV
kW
7. 7
26
12.1
41
16.5
56
24.8
85
29.7
101
34.7
118
(Btu/h) x (1000)
Approximate
Heat Output
kW
7. 1
24
11.1
38
15.1
52
23
78
27.2
93
31.7
108
(Btu/h) x (1000)
Natural Gas (G20) Data - Inlet Pressure 20 mbar (7.8 in WG) Min. 17 mbar (6.8 in WG) Max. 25 mbar (10 in WG)
Burner Pressure
mbar
9.5
9.5
9.5
9.5
9.0
9.0
m3/h
ft3/h
0.8
29
1.3
45
1.7
62
2.6
93
3.1
110
3.6
127
Gas Rate
Natural Gas (G25) Data - Inlet Pressure 25 mbar (10 in WG) Min. 20 mbar (7.8 in WG) Max. 30 mbar (12 in WG)
Burner Pressure
mbar
9.0
9.0
9.5
9.2
9.2
9.3
m3/h
ft3/h
0.9
33
1.5
52
2.0
72
3
108
3.6
127
4.2
148
Gas Rate
LPG / Propane (G31) Data - Inlet Pressure 37 mbar (14.6 WG) Min. 25 mbar (10 in WG) Max. 45 mbar (18 in WG)
Alternative where permitted 50 mbar (20 in WG) Min. 42.5 bar (17 in WG) Max. 57.5 mbar (23 in WG)
Burner Pressure
mbar
25.6
29.4
29.4
28.6
29.9
29.9
m3/h
0.3
0.16
0.5
0.25
0.7
0.34
1
0.51
1. 2
.61
1. 4
.71
Gas Rate
kg3/h
LPG / Butane (G30) Data - Inlet Pressure 29 mbar (11,4 in WG) Min. 20 mbar (7.8 in WG) Max. 35 mbar (13.8 WG)
Burner Pressure
mbar
19.2
21.9
22.9
21.4
21.4
22.4
m3/h
0.2
0.09
0.4
0.14
0.5
0.19
0.8
0.29
.9
.34
1. 1
.42
Gas Rate
kg3/h
Gas rates corrected to standard conditions 1013.25 mbar 15° C.
6
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SECTION 5: HEATER INSTALLATION
SECTION 5: HEATER INSTALLATION
5.1 General
5.3 Wall Mounting
Heaters are designed for installation above 1.8 m.
These heaters must be installed within the heated
space. Duct delivery systems are not permitted with
axial fans. When handling or supporting the heater
from below, ensure that the weight is taken at the
support points.
For typical suspension, See Page 8, Figure 3.
Heaters blowing parallel to the wall can only be
installed with the service door away from the wall.
The wall mounting brackets must be attached to a
suitable wall through all mounting holes. Screw
sizes less than M10 may not be used. In order for
the wall mounting brackets to adequately carry the
weight of the heater, it must be installed with best
building practice.
5.2 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 7, Figure 2.
Figure 2: Suspension Methods
Ensure all suspension hardware
is torqued to a minimum
of 27 Nm (20 ft lbs).
Unistrut
Channel Nut
Washer
Nut
10 mm
Steel
Drop Rod
Cone Point
Set Pin
Window
Clamp
10 mm
Steel
Drop Rod
Unistrut
Nut
Washer
Description
Shelf Mounting Bracket
Kit
Shelf Mounting Bracket (2)
Screw #10 x 1/2"
Type AB Phil HWH Z (2)
Part Number Qty.
11111510K
Riv
Nut
111111510
94311008
2
2
Support Points
Shelf Mounting
Brackets
NOTE: For vertical installations, use the mounting points on the rear of the unit.
Existing cabinet screws must be re-used.
7
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
Figure 3: Shelf Mounting and Hanging Suspension
Shelf Mounting
Hanging
Shelf
M10 Fasteners
Mounting
Brackets
(Fasten to
Wall Mounting
Bracket)
Wall Mounting
Bracket Arm
(Right & Left)
M8 Bolt
Washer
Lock Washer
M8 Locknut
Torque to 4.5 Nm (40 in lb)
Wall Mounting
Bracket Diagonal
Wall Mounting
Bracket Vertical
Description
Part Number
Qty.
1
1
1
2
2
6
6
6
Wall Suspension Mounting Bracket Kit
Wall Mounting Bracket Arm Left
Wall Mounting Bracket Arm Right
Wall Mounting Bracket Vertical
Wall Mounting Bracket Diagonal
M8 x 85 mm Hex Head Bolt
M8 Lock Nut with Nylon Insert
M8 Flat Washer
11111511K
111WALL1L
111WALL1R
111WAL2
Description
Part Number
11111512K
1111510K
Qty.
1
1
Wall Shelf Mounting Bracket Kit
Wall Suspension Mounting Bracket Kit
Shelf Mounting Bracket Kit
111WAL3
11111511K
1
97311405
92204504
95204502
96404502
M8 Lockwasher
6
Hardware provided to construct mounting bracket assembly only.
Figure 4: Vertical Louvres (Optional)
Remove Horizontal
Louvres
Install Vertical
Louvre Brackets
(top and bottom)
with supplied
screws.
Install Vertical
Push in
Louvres and Springs
into Brackets
Louvre and compress
spring to remove
(opposite end first)
with Springs at Top
Description
Part Number
11111902K
Description
Part Number
11111900K
Description
Vertical Louvre Kit
CTCU 7 and 11
Vertical Louvre Bracket
#10 Screw
Part Number
11111901K
Vertical Louvre Kit
CTCU 27 and 32
Vertical Louvre Bracket
#10 Screw
Vertical Louvre Kit
CTCU 15 and 22
Vertical Louvre Bracket
#10 Screw
11111903
S103
11111903
S103
11111903
S103
27-32 Vertical Louvre
Instruction Sheet
11111902
91040021
Instruction Sheet
91040021
CTCU 7-11 Vertical Louvres
Louver Spring
Instruction Sheet
11111901
90901200
91040021
For models 15 and 22, horizontal louvres are re-used.
8
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SECTION 6: FLUE INSTALLATION
SECTION 6: FLUE INSTALLATION
6.1 Changing Flue and Air Intake Orientation
Figure 5: Flue and Roof Detail
The heater is sold with horizontal flue and fresh air
connections as standard. If vertical flue and fresh air
connections are required, follow the instructions on
Page 29, Section 15.4.
Flue
Terminal
6.2 Flue Installation
WARNING
Masterflash
Soaker Flashing
or Rain Collar.
Roof
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.
Metal Sleeve
Failure to follow these instructions can result in death,
injury or property damage.
Flue
25 mm Air Gap to
Combustible Material
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 9, Figure 5 through
Page 10, Figure 7. 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 9, Figure 5 through
Page 10, Figure 7.
6.3 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 10, Figure 7. The wire mesh
inside the fresh air adapter on the heater must be
removed prior to installation.
6.4 Type B22 Appliance
The flue must be fitted with a low resistance
terminal. See Page 9, Figure 5 through Page 10,
Figure 6.
9
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
Figure 6: Vertical and Horizontal Flue Termination - Type B22 Appliance
Roof Terminal
Masterflash
Flue
Vertical
Option
Masterflash
Flue
Horizontal
Option
Wall
Terminal
Figure 7: Vertical and Horizontal Flue Termination - Type C12 C32 & C62 Appliances
Roof Terminal
Plastic Cup
Masterflash
Manifold
Air Intake
Vertical
Option
Flue
Remove Internal
Horizontal
Option
Wall
Plate
Wire Mesh
Flue
Air Intake
Wall
Terminal
Manifold
Remove Internal
Wire Mesh
10
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SECTION 7: AIR SUPPLY
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.
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.
7.2.1 Heaters Installed Within the Heated Space
Where the volume of the heated space is greater
than 4.7 m3 per kilowatt of total rated heat input and
the air change rate is at least 0.5/h, additional high
and low level ventilation will not be required.
For a building having an air change rate less than
0.5/h, 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
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 CTCU heater.
11
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 8: GAS PIPING
8.1 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.
WARNING
• The gas supply pipe is adequately sized to carry
the total volume of gas for the complete
installation.
Fire Hazard
• An isolating valve and union connection should
be used and fitted into the supply adjacent to the
heater.
Connect gas supply according to Figure 8.
Gas can leak if not installed properly.
Failure to follow these instructions can result in death,
injury or property damage.
• 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.
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.
IMPORTANT - The complete installation must be
purged and tested for gas soundness in accordance
with local and national codes.
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 8: Gas Connection with Stainless Steel Flex Connector
• Hold gas nipple securely
with pipe wrench when
attaching the flex gas
connector.
Option A:
Stainless Steel
Flex Gas
• Do not twist flexible
gas connector.
Connector
• Ensure all joints are
gas tight.
Do not bend flexible
gas connector sharply.
Option B:
Medium or Heavy
Gauge Tubing
Gas Connector
Gas Isolating Valve
Drip Leg
Cap
Union
Connection
12
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SECTION 9: WIRING AND ELECTRICAL INFORMATION
SECTION 9: WIRING AND ELECTRICAL INFORMATION
9.1 Electrical Supply 9.2.3 Remote Frost Thermostat
All heater models need a constant 230 V 50 Hz 1 Ø When required, connect to L1 and T2 parallel to the
supply connected to terminals L1, N & Earth.
room thermostat. Locate within the heated space
adjacent to the most vulnerable equipment that
requires protection. See Page 14, Section 9.3.
Polarity "L & N" must be correct. The voltage
between neutral and earth should be 0 and never
exceed 15 volts.
9.2.4 Remote Fan Controls
All heaters and controls must be correctly earthed.
The fan will operate automatically providing there is
a constant 230 V supply.
All external wiring must comply with the relevant
local codes. Wire specification H05VV-F.
A switch or control wired between L1 and T1 will
allow external control of the fan(s).
External controls must have the same constant
230 V 50 Hz supply.
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.
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. This switch
should be fused to 5 A.
The final connection to the heater should be made
by flexible cable or conduit to the 7 pole plug using 1
mm2 cable on all models.
WARNING
Electrical Shock Hazard
Disconnect electrical power before servicing.
Failure to follow these instructions can result in
death or electrical shock.
9.2 Remote Controls
The heater is designed to be operated by controls
installed remote from the heater. See Page 14,
Section 9.3.
9.2.1 Burner Controls (Thermostat)
Controls to operate the burner must be connected
between L1 and T2.
9.2.2 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.
13
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
9.3 CTCUA Wiring Diagram Models 7 - 32
SITE WIRING
BLUE
BROWN
YELLOW
WHITE
YELLOW
BLACK
WHITE
BLACK
BROWN
PINK
PRESSURE SWITCH
7 POLE PLUG
PURPLE
GREY
BROWN
7 POLE SOCKET
COMBUSTION FAN
AXIAL FAN
230 V
50 Hz
SUPPLY
FAN DELAY THERMOSTAT
EMC FILTER
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.
14
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SECTION 10: COMMISSIONING
SECTION 10: 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
1. Check that all site wiring is connected in
accordance with the appropriate wiring diagram
on Page 14, Section 9.3.
2. Check the correct fuse size is fitted;
See Page 13, Section 9.1.
components are accessed via the door secured by 4
sheet metal screws. Opening the door exposes live
electrical connections and hot components.
10.1.3 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.
WARNING
10.1.4 Mechanical Checks
1. Check that the fan is 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.
Electrical Shock Hazard
Use extreme caution while commissioning.
NOTE: The limit thermostat is sealed at the factory
and is not adjustable.
Failure to follow these instructions can result in
death or electrical shock.
10.2 Begin Commissioning
10.2.1 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.
10.1 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.
1. Turn off the isolating gas valve.
2. Using the installed external control, turn on the
burner. The automatic sequence will now begin
as described on Page 16, Figure 9.
There will be no ignition of the burner and lockout
will occur, which proves the controls are operating
correctly.
10.1.1 Louvres
Where fitted, the air delivery louvres need to be set
during commissioning to give the required air
distribution (optional vertical louvres).
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.
10.1.2 Electrical Checks
All pre-commission checks must be carried out
before commissioning the heater.
15
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
Figure 9: Automatic Burner Control Box Sequence
Burner sequence for Honeywell S4565C
CLOSE
DOWN
START
RUN
Supply 230 V
Flue Fan
30 Sec. Purge*
NO
Pressure Switch
C
P
NC
ts = 10 seconds
Ignition Spark
Start Gas Valve
Flame Signal
Required Incoming Signals
Signals Output By Control
*Purge time begins at pressure switch change over.
If at any stage the flame fails, the control will go into "lockout". The red light inside the RESET
switch will illuminate and the control will need to be manually reset before any further start
attempt can be made.
Figure 10: Gas Valve for Heater Models 7 - 32
End View
Screw
Ignition
Output
Ignition Control
(Plugs into Gas Valve)
Flame
Probe
Connection
Regulator
(Under Cover)
12 Cable Connector
Outlet Pressure
Inlet Pressure
Gas Inlet
16
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SECTION 10: COMMISSIONING
10.2.2 Commissioning the Gas Valve (All Gases) 10.2.5 Turning Off the Heater
10.2.2.1 Check Burner Gas Pressure
1. Loosen the screw cover of the outlet (burner)
pressure test point and connect a manometer.
Set the external controls to the "OFF" position and
the main burner will stop.
The fan will run until it is 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.
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 6, Section 4.3.
10.2.6 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.
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 6, Section 4.3 for inlet pressure requirement.
Do not continue to adjust the regulator if the
pressure is not changing.
10.3 Complete the Commissioning
Ensure that all covers are fitted correctly and all test
points are properly sealed.
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.
10.3.1 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 18,
Section 11 through Page 19, Section 11.5 and all
warnings defined in this manual.
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.
10.2.3 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 CO2
should be between 5.7% to 8.0% for natural gas and
6.8% to 9.2% 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
130° C to 160° C. Seal test hole in flue after testing.
10.2.4 Pressure Switch
The pressure switch is factory pre-set for each
model and is not adjustable.
17
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 11: USER INSTRUCTIONS
11.1 User Instructions
The CTCU heaters are fully automatic and operate
from the external controls fitted on site.
Press to reset
The only user controls at the heater are the:
Burner Lockout
Reset Button ................See Page 18, Section 11.3.3
Limit Thermostat ResetSee Page 18, Section 11.3.2
These are hand reset devices to give further
protection against fan failure.
WARNING
NOTE: To reset, the heat exchanger must be cool.
Description
Part Number
Limit Thermostat
90412100
WARNING
Electrical Shock Hazard
Disconnect electrical power before servicing.
Failure to follow these instructions can result in
death or electrical shock.
Explosion Hazard
11.2 Heater Operation
If control locks out, do not make more than 3
attempts to restart the heater.
When the heater has been switched on by the
remote controls installed on site, the main burner will
automatically turn on.
Dangerous gas mixtures can build up.
The burner control box will control the safe ignition
of the flame.
The fault must be traced and repaired by a
registered installer or service engineer.
All heaters require a constant gas and electricity
supply which must not be interrupted during the
normal operation of this heater.
Failure to follow these instructions can result in
death, injury or property damage.
11.3.3 Burner Lockout Reset Button
Figure 11: Heater Operating Sequence
The red warning light on the back 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.
ON
CLOSE
DOWN
THERMOSTAT
CALL FOR
HEAT
ON
BURNER
RUN
11.4 Lighting Instructions
11.4.1 To Turn On Heater
1. Ensure that the electrical and gas supplies to
the heater are on. Check that the on site con-
trols are “ON”.
ON
2-3 MINUTES
RUN ON
FAN
11.3 Common User Controls
11.3.1 Fan Thermostat
The fan thermostat is located inside the access door
NOTE: The thermostat setting must be above the
ambient temperature for the heater to operate.
at the top of the heater. See Page 28, Section 15.3.
This control ensures the heater does not blow cold
air in the normal heating cycle.
2. The automatic firing sequence will begin as
described on Page 16, Figure 9. 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 18, Section 11.3.3.
11.3.2 Limit Thermostat
The limit thermostat is located inside the access
door of the heater. See Page 28, Section 15.3. This
control protects the heat exchanger against
overheating.
18
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SECTION 11: USER INSTRUCTIONS
11.4.2 To Turn the Heater Off
Set the installed remote controls to the "OFF"
position.
The burner will turn off immediately.
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
The fan will continue to run for a few minutes.
To restart, turn the control used above to "ON".
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
11.5 Simple Fault Finding
5. Leave the building.
Some possible reasons for the heater not operating
are:
1. Gas supply not turned "ON".
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.
2. Electricity supply not turned "ON".
3. The time and/or temperature controls are not
"ON".
WARNING
4. The limit thermostat may have operated. This
may be caused by an interruption of the electri-
cal supply or failure of the distribution fan.
If the limit thermostat persistently operates, there is
a fault which must be investigated by a contractor
qualified in the installation and service of gas-fired
heating equipment.
Fire Hazard
Do not store or use petrol or other
flammable vapours and liquids in the
vicinity of this or any other appliance.
11.5.1 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
back of 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 back of the heater.
Some objects will catch fire or explode
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
damage.
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.
19
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 12: SERVICING
12.1 Servicing Instructions
2. Clean any deposits from the main burner which
may have formed in the injectors or venturi of
the burner. See Page 27, Section 15.2.
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 Code and Annual Inspections: All
installations and service of ROBERTS GORDON®
products must be performed by a contractor qualified in
the installation and service of gas-fired heating
equipment 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® products
and perform service where necessary, using only
ROBERTS GORDON® replacement parts.
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.
12.3 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 and use a
small brush or duster to clean the fan blades from
each side. Replace fan when done.
12.4 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.
WARNING
12.5 Gas Control Valve Maintenance
No regular maintenance is required on this device.
To change gas control valves, See Page 26, Step
15.1 and Page 30, Section 15.5.
Do not repair or disassemble on site.
Replace faulty gas valves with genuine
ROBERTS GORDON® replacement parts.
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.
12.6 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 three screws at the mounting
plate. Remove the four screws attaching the
mounting plate to the fan inlet (See Page 29,
Section 15.4). Ensure that the fan is free to run and
that the fan wheel is clean.
NOTE 1: After any maintenance or repair work,
always test fire the heater in accordance with the
commissioning instructions on Page 15, Section 10
through Page 17, Section 10.3.1 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 22,
Section 14 through Page 25, Section 14.5.
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.
12.2 Burner Maintenance
1. Open the door and remove the burner compart-
ment cover. See Page 27, Section 15.2.
20
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SECTION 13: CONVERSION BETWEEN GASES
SECTION 13: CONVERSION BETWEEN GASES
13.1 General
Conversion between gases will require a change of
burner injectors and the gas valve re-commissioning
to the new conditions.
13.2 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 27, Section 15.2.
2. Remove the 4 screws holding the manifold and
pull out the manifold.
3. Remove inshot burners by rotating them and
sliding out the bracket.
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.
13.3 Gas Valves
All gas valves used on the CTCU 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 6, Section 4.3.
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.
21
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 14: TROUBLESHOOTING
14.1 General
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.
Start
Are gas & electrical
supplies on?
No
Turn on supplies.
Yes
Is Red lockout
Yes
No
Use 14.2 to test burner.
Use 14.5 to test fan.
warning light on?
No
Does the fan run?
Yes
With external controls on,
does the burner continue
through the heating cycle?
The limit thermostat has
tripped.
See Section 11.3.2.
Has burner “Locked Out”?
No
No
Replace limit thermostat.
No
Yes
Yes
Use 14.2 to test burner.
Replace axial fan.
Yes
If problems persist, contact
Roberts-Gordon Ltd. at
Tel: +44 (0)1902 498733
Heater Operating
TROUBLESHOOT ENDS.
No
For your safety and optimum heater performance, use only ROBERTS GORDON® replacement parts.
Conduct Commissioning procedure as shown on Page 15, Section 10.
22
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SECTION 14: TROUBLESHOOTING
14.2 Troubleshooting For Automatic Ignition Burner Systems
WARNING
Start
Are gas & electrical
Turn on supplies.
Turn on controls.
No
No
supplies on?
Electrical Shock Hazard
Do not touch ignition components.
Voltage from ignition components is high.
Yes
Are external controls on?
Failure to follow these instructions can
result in death or electrical shock.
Yes
Press in lockout reset button
on rear of heater or remote
reset button if fitted.
Is red lockout light on?
Yes
No
No
Is 230 V supply at fan
connections?
Does flue fan run?
Yes
Flue fan faulty; replace
No
Burner control faulty or plug
in connections faulty. Repair
or replace as necessary
Yes
Check for too much flue/air inlet
duct. Check for blockage in
combustion air circuit.
Check for faulty air pressure
switch. See Section 15.5.
Does air pressure switch
change over?
No
Yes
Is HT lead okay and
Ignition control faulty;
replace.
Wait 30 - 40 seconds.
connected?
No
No
Yes
Yes
Is ignition spark operating?
Is spark electrode okay?
See Section 15.6.
Yes
Is the gas valve operating?
To test valve,
Replace valve.
Does the flame light?
No
See Section 14.4.
Yes
Is the flame current at
least 1 µAmp DC when
the flame lights?
Trace fault in supervision
system. See Section 14.3.
Is red lockout light on?
Yes
No
If problems persist, contact
Roberts-Gordon Ltd. at
Tel: +44 (0) 1902 498733
Heater Operating
TROUBLESHOOT ENDS.
No
For your safety and optimum heater performance,
use only ROBERTS GORDON® replacement parts.
Conduct Commissioning procedure as shown
on Page 15, Section 10.
23
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
14.3 Troubleshooting for Flame Supervision System
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.
START
Connect a DC ammeter in
series with the flame probe.
Is the flame present and
Use Section 14.1 to
at least 1 µA DC flame
current?
No
Yes
Yes
trace the fault.
Yes
Is the connecting lead
damaged? Is the flame probe
damaged or touching earthed
components?
Is there a current flowing in the
flame probe circuit with no
flame present?
Repair or replace as
necessary.
Yes
Yes
No
Is inlet burner gas pressure
correct? Is live and neutral
polarity correct? Is
Does “lockout” occur when
there is a flame present?
Control box faulty.
Replace with correct type.
flame probe circuit correct?
No
Repair or replace as
necessary.
No
If problems persist, contact
Roberts-Gordon Ltd. at
Heater Operating
TROUBLESHOOT ENDS.
No
NOTE: Minimum flame probe current 1 μA DC. Typical flame probe current 3-5 μA DC.
24
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SECTION 14: TROUBLESHOOTING
14.4 Troubleshooting for Solenoid Valves
START
Is gas pressure at inlet of the
valve correct for gas type?
Note pressure found.
No
No
Fault elsewhere.
Yes
Valve or ignition control
faulty. Replace with
one of correct type.
Does gas pressure at outlet
of the valve rise when
valve turns on?
Yes
Does gas pressure at
outlet of valve return to zero or
lower when valve turns off?
Valve faulty.
Replace with one of
correct type.
No
No
Yes
If problems persist, contact
Roberts-Gordon Ltd. at
Tel: +44 (0) 1902 498733
Valve Operating
TROUBLESHOOT ENDS.
14.5 Troubleshooting for Main Fan
START
Is power supply 230 V at
terminals T1 to N?
Is there 230 V between
terminals L1 and N?
Does fan run
automatically?
Replace fan
delay thermostat.
No
No
Yes
Yes
Fan motor faulty.
Replace with correct type.
Yes
Does fan turn on and
off while burner is firing
continously?
Replace fan
delay thermostat.
Yes
No
If problems persist, contact
Roberts-Gordon Ltd. at
Tel: +44 (0) 1902 498733
Fan Operating
TROUBLESHOOT ENDS.
No
For your safety and optimum heater performance, use only genuine ROBERTS GORDON® replacement
parts.
Conduct Commissioning procedure as shown on Page 15, Section 10.
25
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 15: REMOVAL AND REPLACEMENT PARTS
See warnings and notes on Page 20, Section 12
before removing or replacing parts.
Burner Components
All serviceable burner parts are accessed by the
door on the side of the heater. Remove the four
sheetmetal screws.
15.1 Gas Valve
Remove the gas supply pipe at the heater inlet.
Disconnect
wire harness
Unplug
control
from
valve.
Remove
fixing
screw.
Ignition
Control
Description
Gas Valve VK4105A
Ignition Control
Part Number
90033403
90434010
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. Check that
all the joints are leak free. Reset gas valve. See
Page 17, Section 10.2.2.
IT IS IMPORTANT THAT ONLY THE CORRECT
GAS VALVE IS USED WHEN REPLACING THESE
CONTROLS.
26
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SECTION 15: REMOVAL AND REPLACEMENT PARTS
15.2 Burner Compartment
Burner
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.
Compartment
Cover
Viewing Port
Flame Probe
Ignition Electrode
Remove flexible
air duct from spigot.
Remove screws and
pull off burner cover.
15.2.1 Burner Injectors
Manifold
Ensure gas tight fitting of injectors.
Ensure correct alignment with burners.
Ensure all pipe joints are gas tight.
Remove manifold
screws and pull
out manifold.
Manifold
Burners
Injectors
Unscrew
Injectors
Manifold
Mounting
Bracket
Gromet
Marking
MODEL
Injector Quantity
Natural Gas (G20)
Injector size mm Ø
in Ø
CTCU-7
CTCU-11
CTCU-15
CTCU-22
CTCU-27
CTCU-32
2
3
4
5
6
7
1.78
0.070
1.85
0.073
1.85
0.073
2.06
0.081
2.057
0.081
2.057
0.081
Marking
50
49
49
46
46
46
RG P/N
91930050
91930049
91930049
91930046
91930046
91930046
Natural Gas (G25)
Injector size mm Ø
in Ø
1.99
0.0785
47
2.06
0.081
2.06
0.081
2.26
0.089
2.261
0.089
2.261
0.089
Marking
46
46
43
43
43
RG P/N
91930047
91930046
91930046
91930043
91930043
91930043
LPG Propane (G31) and LPG Butane (G30)
Injector size mm Ø
in Ø
1.18
0.0465
56
1.18
0.0465
56
1.18
0.0465
56
1.25
0.049
1.25
0.049
1.25
0.049
Marking
1.25
1.25
1.25
RG P/N
91930056
91930056
91930056
91930125
91930125
91930125
27
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
15.3 Ignition Electrode and Flame Probe
Burners
Flame
Probe
Limit
Thermostat
Flame
Probe
Fan
Thermostat
Ignition
Electrode
Ignition
Electrode
.120
(3 mm)
spark
gap
Burners
Burner Compartment
Front Views
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
90427411
90439300
92000002
90412102
90412100
Spark Electrode
Automatic Ignition Flame Probe
Burners
Fan Thermostat
Limit Thermostat
28
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SECTION 15: REMOVAL AND REPLACEMENT PARTS
15.4 Flue Fan Vertical Installation
To remove the fan, remove 3
screws securing the fan and
mounting plate to the vent box.
To remove the fan from the
mounting plate, remove the 4
screws.
Intake &
Exhaust Covers
Refit in reverse order.
Mounting Plate
to Vent Box
fixing screws
Air Intake
Adapter
Gaskets
To change the flue and air
intake orientation from back to
top, remove the fan and
mounting plate as above.
Vent Box
Mounting Plate
to Flue Fan
fixing screws
Remove intake and exhaust
covers from top of the heater.
Rotate the fan, mounting plate
and gasket clockwise until the
flue adapter lines up with the
top hole. Secure with 3 screws.
Air Intake Adapter
Intake &
Exhaust
Covers
Gasket
Remove the flexible duct from
the air intake adapter on the
back.
Flexible Duct
Remove the air intake adapter
from the back of the heater and
install in the appropriate hole on
top. Reconnect the flexible duct.
Install intake and exhaust
covers over the back holes.
Mounting Plate
Ensure sealed joints.
Ensure mounting plate orifice is
clear and not obstructed.
to Vent Box
fixing screws
MODEL
CTCU-7
CTCU-11
Fasco
CTCU-15
CTCU-22
CTCU-27
CTCU-32
Fasco
Fasco
Torin
S6818
Sit Controls Sit Controls
Flue Fan
RG P/N
Air Plate
7021-11767 7021-11768 7021-11769
P1210838
90710460
109.2
P1210838
90710460
109.2
90710470
35
90710470
44
90710470
57
90710460
64
mm Ø
in Ø
1.38
1.75
2.25
2.50
4.3
4.3
RG P/N
11111210
11112210
11113210
11114210
11115210
11115210
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 18, Section 11.
29
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL
15.5 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.
Carry out a commission after working on or
changing a pressure switch. See Page 15, Section
10.
Pressure Switch
RG P/N
CTCU-7
90439812
orange
0.45
CTCU-11
90439812
orange
0.45
CTCU-15
90439812
orange
0.45
CTCU-22
90439803
grey
CTCU-27
90439803
grey
CTCU-32
90439803
grey
Colour Code
Set Point mbar
in wc
1.02
1.02
1.02
0.18
0.18
0.18
0.41
.041
.041
30
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SECTION 15: REMOVAL AND REPLACEMENT PARTS
15.6 Ignition Control
15.8 Fan and Limit Thermostats
The control plugs onto the gas valve. Pull out 12 pin 15.8.1 Removal and Replacement
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.
1. Pull off the electrical connections to the
thermostat
2. Unscrew the two screws securing the
thermostat
3. Fit a new thermostat with two screws ensuring
that the correct temperature setting and type
are selected.
See Page 6, Section 4.3.
15.7 CTCUA Axial Fan/Guard/Motor Assembly
The axial fan unit for the CTCUA heater is
supplied completely assembled and balanced.
4. Reconnect the electrical connections and test
operation.
15.7.1 Fan Removal and Replacement
Remove the screws
and washers.
Description
Part Number
11111910
11111911
11111920
11111921
11111922
Axial Fan CTCU-7
Axial Fan CTCU-11
Axial Fan CTCU-15
Axial Fan CTCU-22
Axial Fan CTCU-27/32
15.7.2 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 14,
Section 9.3 wiring diagram.
• Use only genuine ROBERTS GORDON®
replacement parts.
31
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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
WARNING
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
Fire Hazard
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.
Some objects can catch fire or explode when placed
close to heater.
IF THE HEATER WILL NOT OPERATE, TO ENSURE YOUR SAFETY,
FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER
Keep all flammable objects, liquids and vapors the
required clearances to combustibles away from 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.
Failure to follow these instructions can result in death,
injury or property damage.
Installation Clearances
Roof Terminal
Clearances to Combustibles
Roof Terminal
15 cm
Air
15 cm
3 m
Intake
50 cm**
10 cm
Flue
Wall
Terminal
25 cm
30 cm
3 m
2.5 - 3.5 m*
*Heaters may be mounted at a higher level if destratification fans are installed.
**80 cm is necessary to service heater
Roberts-Gordon, LLC
1250 William Street
P.O. Box 44
Buffalo, NY 14240-0044 USA
Telephone: 716.852.4400
Fax: 716.852.0854
Roberts-Gordon Europe Limited
Oxford Street
Bilston, West Midlands WV14 7EG UK
Telephone: +44(0) 1902 494425
Fax: +44(0) 1902 403200
Service Telephone: +44(0) 1902 498733
Service Fax: +44(0) 1902 401464
E-mail: [email protected]
E-mail: [email protected]
Toll Free: 800.828.7450
Installation Code and Annual Inspections: All installations and service of ROBERTS GORDON® products must be performed by a contractor qualified in the installation and service of products 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® products and perform service where necessary, using only ROBERTS GORDON® replacement parts.
Further Information: Applications, engineering and detailed guidance on systems design, installation and product performance is available through ROBERTS GORDON® representatives.
Please contact us for any further information you may require, including the Installation, Operation and Service Manual.
This product is not for residential use.
This document is intended to assist licensed professionals in the exercise of their professional judgement.
© 2006 Roberts-Gordon, LLC All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means – graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage
and retrieval systems – without written permission of Roberts-Gordon, LLC.
Printed in U.S.A.
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