- Roberts-Gordon user guide heater CTCU 7, CTCU 11, CTCU 15, CTCU 22, CTCU 27, CTCU

ManualsBrandsRoberts Gorden ManualsFanCompact Tubular Unit Heaters CTCU 15

Quality in Any Language™

C mbat

Installation, Commissioning,

Operation & Service Manual

Models CTCU 7

CTCU 11

CTCU 15

CTCU 22

CTCU 27

CTCU 32

P/N 11110 0 U K R ev B 10/ 0 6

Compact Tubular Unit Heaters

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.

Roberts-Gordon Europe Limited

Oxford Street

Bilston, West Midlands WV14 7EG UK

Telephone: +44(0) 1902 494425

Fax: +44(0) 1902 403200

Service Telephone: +44(0) 1902 498733

Service Fax: +44(0) 1902 401464

E-mail: uksales@rg-inc.com

E-mail: export@rg-inc.com

www.rg-inc.com

Summary of content (40 pages)

PAGE 1
FOR YOUR SAFETY If you smell gas: 1. Open windows. 2. DO NOT try to light any appliance. 3. DO NOT use electrical switches. 4. DO NOT use any telephone in your building. 5. Leave the building. 6. Immediately call your local gas supplier after leaving the building. Follow the gas suppliers instructions. 7. If you cannot reach your gas supplier, call the Fire Department.
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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 .......................
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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 ..................................................
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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.
PAGE 8
COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL SECTION 1: HEATER SAFETY Your Safety is Important to Us! This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnings in these sections. clearances to combustibles. Affix the tag on a wall near the heater. 2.
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SECTION 3: CRITICAL CONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS 3.1 Basic Information CTCU heaters have automatic ignition burners for ON/OFF operation only. 3.8 Flue Choose heater siting to allow for the proper location of the flue. Each heater must be fitted with an individual and correctly sized sealed flue system (See Page 9, Section 6). 3.2 Location and Suspension No other appliance may be connected to the flue.
PAGE 10
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.
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SECTION 4: SPECIFICATIONS SECTION 4: SPECIFICATIONS 4.
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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 Total Electrical Load W 260 274 336 384 345 Run Current A 1.1 1.2 1.5 1.7 1.5 Start Current A 1.7 1.8 2.5 2.9 2.6 Air Flow m3/h 1120 1220 2710 2750 4474 Sound Pressure Level at 3 m [NR] dB(A) [31] 37 [35] 41 [39] 45 [42] 48 [42] 48 mm Ø 80 80 80 80 100 m 2.
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SECTION 5: HEATER INSTALLATION SECTION 5: HEATER INSTALLATION 5.1 General 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. 5.2 Shelf Mounting and Suspension WARNING 5.3 Wall Mounting For typical suspension, See Page 8, Figure 3.
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL Figure 3: Shelf Mounting and Hanging Suspension Shelf Mounting Hanging Shelf Mounting Brackets (Fasten to Wall Mounting Bracket) Wall Mounting Bracket Arm (Right & Left) Wall Mounting Bracket Diagonal Wall Mounting Bracket Vertical Description Wall Shelf Mounting Bracket Kit Wall Suspension Mounting Bracket Kit Shelf Mounting Bracket Kit M10 Fasteners M8 Bolt Washer Lock Washer M8 Locknut Torque to 4.
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SECTION 6: FLUE INSTALLATION SECTION 6: FLUE INSTALLATION 6.1 Changing Flue and Air Intake Orientation 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. Figure 5: Flue and Roof Detail 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.
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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 Remove Internal Wire Mesh Flue Horizontal Option Wall Plate Flue Air Intake Remove Internal Wire Mesh 10 M
PAGE 17
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.
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL SECTION 8: GAS PIPING WARNING Fire Hazard 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. 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.
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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 Polarity "L & N" must be correct. The voltage requires protection. See Page 14, Section 9.3.
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL 9.
PAGE 21
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 components are accessed via the door secured by 4 sheet metal screws. Opening the door exposes live electrical connections and hot components.
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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 RUN START CLOSE DOWN Supply 230 V Flue Fan Pressure Switch P NO C 30 Sec. Purge* NC ts = 10 seconds Ignition Spark Start Gas Valve Flame Signal *Purge time begins at pressure switch change over. Required Incoming Signals Signals Output By Control If at any stage the flame fails, the control will go into "lockout".
PAGE 23
SECTION 10: COMMISSIONING 10.2.2 Commissioning the Gas Valve (All Gases) 10.2.2.1 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 Technical Data Tables for the correct gas and model on Page 6, Section 4.3.
PAGE 24
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. The only user controls at the heater are the: Burner Lockout Reset Button ................ See Page 18, Section 11.3.3 Limit Thermostat Reset See Page 18, Section 11.3.2 Press to reset These are hand reset devices to give further protection against fan failure.
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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. The fan will continue to run for a few minutes. To restart, turn the control used above to "ON". 11.5 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 limit thermostat may have operated.
PAGE 26
COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL SECTION 12: SERVICING 12.1 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.
PAGE 27
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.
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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 Use 14.2 to test burner. No Use 14.5 to test fan.
PAGE 29
SECTION 14: TROUBLESHOOTING 14.2 Troubleshooting For Automatic Ignition Burner Systems WARNING Start Are gas & electrical supplies on? No Turn on supplies. Electrical Shock Hazard Do not touch ignition components. Yes Voltage from ignition components is high. Are external controls on? No Turn on controls. Yes Press in lockout reset button on rear of heater or remote reset button if fitted. Failure to follow these instructions can result in death or electrical shock.
PAGE 30
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 at least 1 µA DC flame current? No Use Section 14.1 to trace the fault.
PAGE 31
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 Fault elsewhere. No Valve or ignition control faulty. Replace with one of correct type. No Valve faulty. Replace with one of correct type. No If problems persist, contact Roberts-Gordon Ltd. at Tel: +44 (0) 1902 498733 www.rg-inc.
PAGE 32
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.
PAGE 33
SECTION 15: REMOVAL AND REPLACEMENT PARTS 15.2 Burner Compartment Burner Compartment Cover Viewing Port Flame Probe 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. Remove flexible air duct from spigot. Remove screws and pull off burner cover. 15.2.1 Burner Injectors Manifold Remove manifold screws and pull out manifold. Ensure gas tight fitting of injectors.
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COMBAT® CTCU UNIT HEATER INSTALLATION OPERATION AND SERVICE MANUAL 15.3 Ignition Electrode and Flame Probe Burners Limit Thermostat Flame Probe 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.
PAGE 35
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. Intake & Exhaust Covers Mounting Plate to Vent Box fixing screws Gaskets Air Intake Adapter Vent Box Mounting Plate to Flue Fan fixing screws Refit in reverse order. To change the flue and air intake orientation from back to top, remove the fan and mounting plate as above. Remove intake and exhaust covers from top of the heater.
PAGE 36
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.
PAGE 37
SECTION 15: REMOVAL AND REPLACEMENT PARTS 15.6 Ignition Control The 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. 15.
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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. WARNING 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.