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Installation, Commissioning, Operation & Service Manual Tubular

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1. 230 V 50 Hz Time Switch 230 V 50 Hz Time Switch Contactor or Relay va Contactor or Relay Single Phase Motor with Load Over 7 Amps L 400 VY 3 G Overload protection must motor 230 V 50 Hz be provided at the motor f supply or contactor Overload protection must be provided at the motor RDW 1565 or contactor N L4 l2Lg 400 V 50 Hz 3 Supply 29 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL SECTION 12 COMMISSIONING ADANGER Electrical Shock Hazard Explosion Hazard Turn off gas supply to Di nnect electri N OAL heater before service before service More than one disconnect switch may be required to disconnect electric from heater Heater must be connected to a i eal grounded electrica source A WARNING Burn Hazard Cut Pinch Hazard Wear protective gear during installation Allow heater to cool before service operation and service Tubing may still be hot after operation Edges are sharp Failure to follow these instructions can result in death electric shock injury or property damage Gas Fired Heater Installation Code and Annual Inspections All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Rob
2. Press in lockout reset button on rear of heater or remote reset button if fitted Is red lockout light on Yes Is 230 V supply at fan connections Does flue fan run No 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 Is HT lead okay and connected Is spark electrode okay Ignition control faulty replace See Section 15 6 Wait 30 40 seconds Is ignition spark operating No Yes Is the gas valve operating To test valve No see Section 15 4 Does the flame light No Replace valve Is the flame current at least 1 uAmp DC when No the flame lights Trace fault in supervision Yes system See Section 16 3 Is red lockout light on If problems persist contact ROBERTS GORDON at Tel 44 0 121 506 7709 www robertsgordon co uk Heater Operating TROUBLESHOOT ENDS NG Conduct Commissioning procedure as shown on Page 30 Section 12 42 of 53 SECTION 16 TROUBLESHOOTING 16 3 Troubleshooting for Flame Supervision System START Connect a DC ammeter in series with the flame probe Is the green light on and at least 1 yA DC
3. a3 SNIVN PRESSURE SWITCH B LOCKOUT RESET NVA WIXV SITE WIRING REMOTE LOCKOUT RESET sa S3 REMOTE LOCKOUT INDICATION Q THERMOSTAT REMOTE FAN ON NEUTRAL GROUND 4d L Eeee pe eee 7 POLE PLUG 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 22 of 53 sat RA TEE 7 POLE SOCKET 230V Y 50HZ SUPPLY SECTION 11 WIRING AND ELECTRICAL INFORMATION 11 4 CTUA Wiring Diagram Models 75 115 GROUND GAS VALVE IGNITION LIMIT THERMOSTAT N C TIME DELAY AXIAL FAN GROUND 1 COMBUSTION FAN MAINS FILTER GREEN YELLOW BLUE LOCKOUT 7 BROWN RS PRESSURE SWITCH GROUND amp GROUND SITE WIRING PRESSURE SWITCH DETAIL GROUND NEUTRAL REMOTE LOCKOUT INDICATION REMOTE 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 23 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 11 5 CTUB C Wiring Diagram Models 40 GROUND GAS VALVE IGNITION H BLACK LIMIT THERMOSTAT N C TIME DELAY AXIAL FAN GROUND CENTRIFUGAL I FAN COMBUSTION FAN MAINS FILTER E 4 GREEN YELLOW BLUE J
4. CENTRI FUGAL FAN 1 MEDIUM BLUE E N H M L GREEN YELLOW 25 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 11 7 CTUB C Wiring Diagram Models 75 115 CENTRIFUGAL CENTRIFUGAL FAN 1 DETAIL FAN 2 DETAIL CENTRIFUGAL FAN 3 DETAIL MEDIUM BLUE BLUE LOW RED MEDIUM BLUE BLUE LOW RED GAS VALVE IGNITION 7 SENSE LIMIT THERMOSTAT N C GROUND BLACK GROUND 1 COMBUSTION FAN MAINS FILTER LOCKOUT QS GREEN YELLOW BLUE BROWN PRESSURE SWITCH GROUND GREEN YELLOW NO P 3 YELLOW LOCKOUT RESET GROUND SITE WIRING lt PRESSURE SWITCH DETAIL GROUND NEUTRAL REMOTE LOCKOUT INDICATION REMOTE 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 26 of 53 521581 TIME DELAY AXIAL FAN TRIGGER 24OVAC 240VAC TIMED INPUT COMMON POWER OUTPUT Siete a a aie ee ae SOO SECTION 11 WIRING AND ELECTRICAL INFORMATION 11 8 CTUD Wiring Diagram Models 40 60 GAS VALVE IGNITION H SENSE GROUND BLACK LIMIT THERMOSTAT N C TIME DELAY AXIAL FAN IGNITION CONTROL GROUND U COMBUSTION FAN MAINS FILTER ella atl LOCKOUT iF BROWN RS PRESSURE SWITCH BLACK GROUND Zz O kS m LOCKO
5. 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 heater Figure 10 Heaters Installed in Isolated Equipment Rooms Le a ga ae Manifold Air Intake 7 l High Level Ventilation 4 Duct Distribution 2 System or 4 Discharge to Heated Space i Return Air Duct from Heated Space or Fresh Air from Outside Max Temperature 32 C N war Room Air Pressure Must Not be Negative Wall Low Level Ventilation y TENE 17 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL SECTION 9 OPTIONAL HEATER CONFIGURATIONS 9 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 Li
6. SECTION 7 FLUE INSTALLATION Page 16 Figure 9 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 15 Figure 7 through Page 16 Figure 9 7 2 Type Ci2 C32 amp Cas 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 16 Figure 9 The wire mesh be fitted inside the fresh air adapter on the heater and must be removed prior to installation 7 3 Type Bz Appliance The flue must terminate outside the building and be fitted with a low resistance terminal See Page 15 Figure 7 through Page 16 Figure 8 Figure 7 Flue and Roof Detail Flue Terminal Masterflash Soaker Flashing or Ram Collar Lag i Metal Sleeve Flue 25 mm Air Gap to Combustible Material 15 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL Figure 8 Vertical and Horizontal Flue Termination Type B22 Appliance lt Roof Terminal Masterflash Metal Sleev
7. SS ei SECTION 10 GAS PIPE WORK SECTION 10 GAS PIPE WORK AWARNING e The gas supply pipe is adequately sized to carry the total volume of gas for the complete installation s An isolating valve and union connection should be used and fitted into the supply adjacent to the heater s For suspended heaters use an approved metal Fire Hazard flexible connection between the isolating valve and the heater To reduce pressure loss use Tighten gas line fittings to connect gas supply one pipe size larger than the heater gas according to Figure 12 connection Flex gas line can crack when twisted g IMPORTANT The complete installation must be Failure to follow these instructions can result purged and tested for gas soundness in accordance in death injury or property damage with local and national regulations e Check the pipe and tubing ends for leaks AWARN l NG before placing heating equipment into ser vice When checking for gas leaks use a soap and water solution never use an open flame Explosion Hazard Leak test all components of gas pipe work before operation Gas can leak if pipe work is not installed properly Do not high pressure test gas pipe work with heater connected 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 connec
8. Shelf Mounting Methods cceeceeeeeeseeeeneeeseees 13 Wall Shelf Mounting and Suspension see 14 Flue and Roof Detail sese 15 Vertical and Horizontal Flue Termination Type Boo Appliance esec e esec eser ereenn ennenen 16 Vertical and Horizontal Flue Termination Type C42 Cas amp Ces Appliances ccecceeeeteeeeees 16 Heaters Installed in Isolated Equipment Rooms 17 Figure S e ale TTT 18 Figure 12 Gas Connection with Stainless Steel Flex CONN CON seis iei at Mesietin tet Hd scalded ads 20 Figure 13 Sequence of Operation Chart eee eee ee 31 Figure 14 Gas Valve for Heater Models 40 60 32 Figure 15 Figure 16 Gas Valve for Heater Models 75 115 32 Heater Operating Sequence eee eee eee ee e 34 Figure 17 Centrifugal Fan Orientation sees eee eee 53 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
9. 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 Regulations All appliances must be installed in accordance with the latest revision of applicable standards and local and national regulations This refers also to the electric gas and venting installation Note Additional standards for installations in public garages aircraft hangars etc may be applicable SECTION 3 CLEARANCES TO COMBUSTIBLES AWARNING Fire Hazard Keep all flammable objects liquids and vapours the minimum required clearances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage 3 1 Required Clearances to Combustibles Clearances are the required distances that combustible objects must be away from the heater to pr
10. 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 17 6 Ignition Control IT IS IMPORTANT THAT ONLY THE CORRECT IGNITION CONTROL SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS 17 6 1 Models 40 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 17 7 CTUA Axial Fan Guard Motor Assembly The axial fan unit for the CTUA heater is supplied completely assembled and balanced 17 7 1 Fan Removal and Replacement Remove the four screws and rubber washers Description Part Number Description _ _ _ _ _ _ _ _ _ _ Axial Fan 16 in Models 40 75 90 90750002 Axial Fan EBM Models 50 60 100 115 90750001 17 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 e Check that the fan blades are free to rotate before turning on the power to the fan e Strictly comply with the colour code of the fan wires to ensure correct operation See Page 22 Section 11 3 through Page 23 Section 11 4 wir ing diagrams s Use only genuine replacement parts sold and supplied by Roberts Gordon Europe Limited 52 of 53 178 CTUB amp CTUC Centrifugal Fan Guard Motor
11. 7 ns mm 7 806 806 756 756 806 806 g in 29 8 31 8 31 8 29 8 29 8 31 8 31 8 maf E E w m m m SK ee f e ee R a f 8 of 53 SECTION 5 SPECIFICATIONS 5 2 CTUB CTUC and CTUD End View End View CTUB C all models CTUC all models L End View Front View CTUD all models CTUD and other models fitted with air outlet spigots Dimension Data CTUB CTUC and CTUD o fe TT T de Mei Mei 42 Me 42 1076 HH G G G G 2 G G3 in oD G G G T TT T Inlet amp Outlet Duct n GG GG ot ma Sa Spigot Height in 21 32 32 40 3 40 3 48 5 48 5 Inlet amp Outlet Duct n 709 707 707 888 888 888 888 Spigo Width in 27 27 8 27 8 35 35 35 35 NOTE Inlet and outlet duct spigot fitted with 30 mm flange 9 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 5 3 General Technical Data Table Model CTU 40 cTu 50 cTu 60 CTU 75 cTu 90 CTU 100 CTU 115 CTUA With Axial Fan Total Electrical Load W 765 655 1420 1420 Totel Electrical Load Wo LS ih ees EIEN Air FI 3 h 4000 6300 6300 7500 7500 12 600 12 600 6300 7500 12 600 12 600 Sound Pressure Level 51 52 1 52 1 52 3 52 3 52 3 52 3 CTUB with Centrifugal Fan and CTUC Range with Centrifugal Fan and Duct Inlet Total Electrical Load 1530 2920 2920 3310 3310 4880 4880 TSR 2 248 28 High Run Curre
12. Assembly The direct drive fan s for the CTUB amp 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 17 8 1 Fan Removal and Replacement 20 mm x 5 mm Adhesive Seal is applied to the flange 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 17 8 2 To Replace the Fan s To reassemble reverse the procedure shown above e Fit new rubber seal between the fan flange and the heater rear panel s Fit to the rear panel in the correct orientation as shown on Page 53 Figure 17 e Strictly comply with the colour code of the fan wires to ensure correct operation See Page 24 Section 11 5 through Page 26 Section 11 7 wiring diagrams e Use only genuine replacement parts sold and supplied by Roberts Gordon Europe Limited 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
13. Burner Pressure in 3 8 3 5 3 9 2 45 2 4 2 5 2 53 m8 h 4 5 5 8 6 6 9 0 10 5 11 3 12 8 Gas Rate ft h 160 206 234 319 371 398 451 Natural Gas G25 Data Inlet Pressure 25 mbar 10 in WG Min 20 mbar 7 8 in WG Max 30 mbar 12 in WG mbar 14 2 8 0 77 9 2 9 3 9 2 10 2 Burner Pressure in 5 7 3 2 3 1 3 7 3 73 3 7 4 1 m8 h 4 78 6 14 6 98 9 49 11 06 11 86 13 43 Gas Rate IS 169 217 247 335 391 419 474 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 mbar 31 4 28 1 272 25 6 273 25 3 25 9 Burner Pressure in 12 6 11 3 10 9 10 27 10 96 10 2 10 4 m8 h k 3 51 4 09 4 39 4 97 kg h 6 50 7 58 8 13 9 21 Gas Rate liquid h d 12 8 14 9 16 0 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 mbar 23 7 19 4 20 2 18 3 19 4 Ia 18 7 Burner Pressure in 9 5 7 8 8 1 7 3 7 8 7 5 1 95 3 09 3 32 3 75 kg h l 4 77 7 55 8 09 9 17 Gas Rate Leni i 13 2 14 1 16 0 Gas Connection Gas rates corrected to standard conditions 1013 25 mbar 15 C 11 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL SECTION 6 HEATER INSTALLATION 6 1 General Heaters are designed for installation above 2 5 m These heaters must be installed within the hea
14. Europe Limited 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 52 Section 178 2 14 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 14 5 Gas Control Valve Maintenance No regular maintenance is required on these devices To change gas control valves See Page 45 Step 171 and Page 51 Section 175 Do not repair or disassemble on site The Vicinity of the Heater SECTION 14 SERVICING Replace faulty gas valves with genuine replacement parts sold and supplied by Roberts Gordon Europe Limited 14 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 50 Section 174 Ensure that the fan is free to run and that the fan wheel is
15. 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 40 of 53 16 1 General START Are gas amp electrical supplies on Turn on supplies Is Red lockout warning light on Use 15 2 to test burner Check limt thermostat Reset With external controls on does the burner continue to fire No Use 15 2 to test burner Check time delat relay Is there 230 V accross brown No and blue wires Is distribution air fan operating Check for mis wiring Change time delay relay If problems persist contact ROBERTS GORDON at Tel 44 0 121 506 7709 www robertsgordon co uk Heater Operating TROUBLESHOOT ENDS Conduct Commissioning procedure as shown on Page 30 Section 12 SECTION 16 TROUBLESHOOTING 41 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 16 2 Troubleshooting For Automatic Ignition Burner Systems To measure flame current connect a 0 50 uA DC meter in series with the flame probe If the meter reads negative values then reverse the test leads Start Are gas amp electrical supplies on Turn on supplies Has the thermostat limit thermodisc operated or light faulty Reset or replace as necessary Is the green light on No Are external controls on Yes
16. clean 14 7 Maintenance Checklist 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 Europe Limited and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilitate optimum performance and safety Roberts Gordon Europe Limited recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equipment and perform service where necessary using only replacement parts sold and supplied by Roberts Gordon Europe Limited Do not store or use flammable objects liquids or vapors near the heater Immediately remove these items if they are present Maintain the clearances to combustibles Do not hang anything from or place anything on the heater Immediately remove objects in violation of the clearances to combustibles See Page 5 and Page 6 Section 3 Vent Pipe Terminals Venting must be intact Using a flashlight look for obstructions cracks on the pipe gaps in the sealed areas or corrosion The area must be free of dirt and dust Remove any carbon deposits or scale using a wire brush If the vent terminal has a screen built in remove any dirt dust or
17. flame current Is there a current flowing in the flame probe circuit with no flame present Yes Does lockout occur when there is a flame present Heater Operating TROUBLESHOOT ENDS No Is the connecting lead damaged Is the flame probe damaged or touching earthed Is inlet burner gas pressure correct Is live and neutral flame probe circuit correct If problems persist contact ROBERTS GORDON at Tel 44 0 121 506 7709 www robertsgordon co uk Use section 15 1 to trace the fault Repair or replace as Yes necessary components Control box faulty Lay Replace with correct type polarity correct Is Repair or replace as necessary NOTE Minimum flame probe current 1 pA DC 16 4 Troubleshooting for Solenoid Valves START Is 230 V at the valve terminals at the appropriate time Fault elsewhere Is gas pressure at inlet of the valve correct for gas type No Fault elsewhere Note pressure found Does gas pressure at outlet of the valve rise when valve turns on Does gas pressure at outlet of valve return to zero or lower when valve turns off Valve Operating TROUBLESHOOT ENDS Valve faulty Replace with one of correct type Valve faulty Replace with one of correct type No If problems persist contact ROBERTS GORDON at Tel 44 0 121 506 7709 www robertsgordon co uk No 43
18. immediately The fan will continue to run for a few minutes To restart turn the control used above to ON 13 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 SECTION 13 USER INSTRUCTIONS 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 13 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 hold the lockout reset button for five seconds If a remote reset is not fitted a reset button is on the rear panel of the heater See Page 8 Section 5 1 Lockout should not occur during normal operation of the heater and indicates there is a fault condition which must be corrected 35 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL SECTION 14 SERVICING ADANGER A WARNING Electrical Shock Hazard Explosion Hazard Burn Hazard Cut Pinch Hazard Disconnect electric Turn of
19. 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 6 of 53 SECTION 4 CRITICAL CONSIDERATIONS 4 1 Ventilation AWARNING Carbon Monoxide Hazard Heaters may be installed vented or unvented Vented heaters must be vented outdoors Unvented heaters must be installed in buildings with ventilation rates as per section 7 Failure to follow these instructions can result in death or injury It is important to ensure that there is adequate air circulation around the heater to supply air for combustion ventilation and distribution in accordance with local and national codes 4 2 Gas Supply AWARNING Fire Hazard Connect gas supply according to Figure 12 Do not use gas supply pipe and electrical connections to support heater s weight 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 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 SECTION 4 CRITICAL CONSIDERATIONS 4 3 Electrical Supply A DANGER Electrical Shock Hazard Disconnect electric before service Heater must be properly grounded Failure to follow these instructions can result
20. in death or electrical shock 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 11 4 4 Flue Choose heater siting to allow for the proper location of the flue Each heater must be fitted with an individual and correctly sized sealed flue system See Section 7 No other appliance may be connected to the flue For room sealed installation the air intake must be the same size sealed system and the flue air intake must terminate at an approved concentric wall or roof terminal 7 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL SECTION 5 SPECIFICATIONS 5 1 CTUA Heater must be Top View supported at these points from above or below E C i 77 D Support Centers 492 End View Z Rear View Air Intake MU wwe Y Electrical H Supply gt i D Gas Supply 7 J 168 o cme lt _ Data CTUA fase a ra ae a 1327 1327 1327 1327 in 42 3 42 3 42 3 52 3 52 3 52 3 52 3 Height ia 680 895 895 1100 1100 1311 1311 g in 26 8 35 2 35 2 43 3 43 3 51 6 51 6 EO ae a 450 627 aa Be ce E an em im pa Ha 312 A ae on ae NE a8 cs its 7 75 a G gt S gt E ia G EaI a G G E E G G mm za aT i aT 2 a aT DEE 2 al G pa a 220 pa S S 5 9 5 9 8 7 8 7 8 7 8
21. is connected in accordance with the appropriate wiring dia grams on Page 22 Section 11 3 through Page 29 Section 11 10 2 Check the correct fuse size is fitted See Page 21 Section 11 1 12 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 regulations Ensure that the air is fully purged from the heater inlet pipe up to the main gas valve inlet test nipple 12 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 SECTION 12 COMMISSIONING 12 4 Begin Commissioning 2 Using the installed external control turn on the 12 4 1 Before Operating the Heater burner The automatic sequence will now begin To ensure that all the controls are in safe working as described on Page 31 Figure 13 order operate the heater for the first time with the There will be no ignition of the burner and lockout isolating gas valve turned off will occur which proves the controls are operating 1 Turn off the gas isolating valve correctly Figure 13 Sequence of Operation Chart KEY TO TO T1 T2 T3 T4 SYMBOLS l b T O Thermo
22. 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 pre set for each model and is not adjustable 12 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 12 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 12 8 Complete the Commissioning Ensure that all covers are fitted correctly and all test points are properly sealed 12 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 SECTION 12 COMMISSIONING 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 34 Section 13 through Page 35 Section 13 5 and all warnings defined in this manual 33 of 53 COMBAT CTU UNIT HEATERS INSTALLATI
23. terminals SECTION 17 REMOVAL AND REPLACEMENT PARTS e Check that the fan blades are free to rotate without catching before turning on the power to the fan e Set all fans to operate at the same speed Figure 17 Centrifugal Fan Orientation CTUB C 40 CTUB C 50 90 CTUB C 100 115 17 9 Fan Data CTUA Models 16 in 500 mm 500 mm 16 in 16 in 500 mm 500 mm Fan Rating 250 250 250 Watts per Fan CTUB C Models 241 241 241 241 241 241 270 270 270 270 270 270 270 270 Normal Fan Raina W Fgh Fan Rtn WW 53 of 53 Attach this information to the wall near the ROBERTS GORDON heater ROBERTS GORDON Read the Installation Commissioning Operation and Service Manual thoroughly before installation operation or service OPERATING INSTRUCTIONS 1 STOP Read all safety instructions on this information sheet 2 Open the manual gas valve in the heater supply line 3 Turn on electric power to the heater 4 Set the thermostat to desired setting above ambient temperature The automatic starting sequence begins NOTE Following long shutdown periods the burner control may go to to LOCKOUT during the start sequence Push the reset button to recommence firing Contact service department if LOCKOUT continues see manual for details TO TURN OFF THE HEATER 1 Turn the thermostat time switch to OFF The burner will turn OFF Fire Hazard immediately but fans will c
24. 040001 Terminal Label 91040022 Part Number 91040030 2 of 53 Terminal Label Address Label SECTION 1 HEATER SAFETY Figure 2 Side Panel Label Placement ACCESS SIDE VIEW OUTSIDE ACCESS SIDE VIEW INSIDE DOOR Wiring Diagram Label WARNING r A Lighting Instructions Label 3 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL SECTION 2 INSTALLER RESPONSIBILITY e To install the heater as well as the gas and electrical supplies in accordance with applicable specifications and regulations Roberts Gordon Europe Limited recommends the installer contact a local authority building inspector or insurance company for guidance e To use the information given in the manual together with the local and national regulations to perform the installation To install the heater in accordance with the clearances to combustibles of this heater To apply all needed materials not supplied as standard equipment s 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 s To never use heater as
25. 5 115 sss 26 11 8 CTUD Wiring Diagram Models 40 60 27 11 9 CTUD Wiring Diagram Models 75 115 28 11 10 CTUD External Motor Alternative Wiring amp Optional Thermostat Time SWwWGh eee eee eee 29 SECTION 12 Commissioning ccssecseeceeeteeseeeeseeeseeeeeeeeee 30 12 1 Pre Commission Checks ee 30 122 Gas Hee 30 12 3 Mechanical Checks 30 12 4 Begin Commissioningd sese eee ee eee ee eee ee 31 12 5 Combustion Testing sese eee eee eee 33 12 6 Turning Off the Healer eee eee eee eee 33 12 7 External Controls eee eee eee 33 12 8 Complete the Commissioning cceeeeeeeee 33 12 9 Instruction to the USEF 00 eee eee 33 SECTION 13 User Instructions sss sss es sse esse esse 34 13 1 User Instructions eee eee eee 34 13 2 Heater Operation ee eee eee 34 13 3 Common User Controls sss eee eee 35 13 4 Lighting Instructions sss esse eee eee eee eee eee 35 13 5 Simple Fault binding sss sese 35 SECTION 14 Servicing csseccssecsseeseeeeseeeseeenseeeseeeeseeeseeeees 36 14 1 Servicing Instructions sese eee eee eee ee eee 36 14 2 Burner Maintenance eee eee 36 14 3 Fan Motor Assembly Maintenance seer ee ee 36 14 4 Heat Exchanger Maintenance sees eee eee eee eee 37 14 5 Gas Control Valve Maintenance see eee 37 14 6 FIUC aT 37 14 7 Maintenance Checklist sese eee 37 SECTION 15 Conversion Between Gases 01sssse 39 151 GMC T H eter ea eee as 15 2 Burner Conversion eee eee ee
26. ECTION 17 REMOVAL AND REPLACEMENT PARTS 17 3 Ignition Electrode and Flame Probe 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 KA ST s L EES u Burner Compartment Front Views Sy PN X i Ignition via Ignition Electrode U 1 1 1 1 i 1 x Z J T K 7 HHHH HH H HHT HT 49 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 17 4 Flue Fan lt Rear Panel Remove screws securing outlet flange to the flue adapter Vent Box gt Screws Flue Outlet Adapter Gasket i Flue Fan Disconnect electrical connections at plug in tabs Remove screws securing flue Vent Box gt a lt Rear Panel fan mounting plate to vent box Remove screws securing Mounting ct ie a mounting plate to fan Refit in reverse Use new gaskets Ensure sealed joints 7 d Ensure mounting plate orifice is Fie Fen Geseis r clear and not obstructed Fan Plate Screws Outlet Gasket Inside of Rear Panel Flue Fan MODEL CTU 40 CTU 50 CTU 60 CTU 75 CTU 90 CTU 100 CT
27. LOCKOUT L BROWN RS PRESSURE SWITCH BLACK GROUND NO P 3 YELLOW GROUND SITE WIRING PRESSURE SWITCH DETAIL REMOTE LOCKOUT INDICATION REMOTE 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 24 of 53 SECTION 11 WIRING AND ELECTRICAL INFORMATION 11 6 CTUB C Wiring Diagram Models 50 60 CENTRIFUGAL FAN 1 DETAIL N HIGH BLACK MEDIUM BLUE BLUE LOW RED GROUND GAS VALVE IGNITION SENSE an eA BLACK GROUND BLACK LIMIT THERMOSTAT N C m IGNITION CONTROL GROUND 8 COMBUSTION FAN MAINS FILTER GREEN YELLOW BLUE LOCKOUT BROWN PRESSURE SWITCH BLACK Y ES GROUND WHITE LOCKOUT RESET Z O G m GROUND SITE WIRING PRESSURE SWITCH DETAIL GROUND NEUTRAL REMOTE LOCKOUT INDICATION REMOTE 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 CENTRIFUGAL FAN 2 DETAIL MEDIUM BLUE BLUE LOW RED TIME DELAY AXIAL FAN TRIGGER 240VAC 240VAC TIMED INPUT COMMON POWER OUTPUT CENTRIFUGAL FAN 2 E N H M L
28. ON OPERATION AND SERVICE MANUAL SECTION 13 USER INSTRUCTIONS A DANGER Electrical Shock Hazard Disconnect electric before service Heater must be properly grounded Failure to follow these instructions can result in death or electrical shock A WARNING Fire Hazard Explosion Hazard Burn Hazard Cut Pinch Hazard Keep all flammable Turn off gas supply to Allow heater to cool Wear protective gear objects liquids and heater before service before service during installation vapors the minimum operation and service required clearances to Tubing may still be hot combustibles away after operation Edges are sharp from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage 13 1 User Instructions Figure 16 Heater Operating Sequence 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 35 Section 13 3 2 Thermostat Limit Thermodisc Reset Button See Page 35 Section 13 3 1 13 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 nor
29. U 115 Flue Fan Torin DSA 508 Torin DSA 524 Torin DSA 524 AO Smith AO Smith AO Smith Torin DSF 128 202 JFIGO98NS JFIGO98NS JFIGO98NS 146 052 077272 077273 077274 RG P N 90710430 90710440 90710440 90710001 90710001 90710001 90710450 Air mm 69 1 69 9 76 2 85 0 103 6 110 5 152 4 Plate in 2 72 2 75 3 0 3 35 4 08 4 35 6 RG P N 11011137 11011136 11011135 11011134 11011133 11011132 11011131 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 34 Section 13 50 of 53 17 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 AWARNING Carbon Monoxide Hazard Use correct pressure switch specified for each model Use of incorrect pressure switch could cause unsafe condidtion 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 30 Section 12 SECTION 17 REMOVAL AND REPLACEMENT PARTS CTU 40 CTU 50 CTU 60 CTU 75 CTU 90 CTU 100 CTU 115 witc RG P N 90439803 90439821 90439810 90439811 90439807 90439811 90439807 Colour grey brown black grey brown grey brown Code Set Point 1 02 95 0 87 1 79 1 69 1 79 1 69 mbar 51 of
30. UT RESET GROUND SITE WIRING PRESSURE SWITCH DETAIL REMOTE LOCKOUT INDICATION REMOTE LOCKOUT RESET NOTE For external fan wiring See Page 29 Section 11 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 27 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 11 9 CTUD Wiring Diagram Models 75 115 GAS VALVE IGNITION SENSE a GROUND BLACK GROUND 3 COMBUSTION FAN GREEN YELLOW BLUE BROWN PRESSURE SWITCH LIMIT THERMOSTAT N C TIME DELAY AXIAL FAN MAINS FILTER LOCKOUT QS GROUND Zz O faa m GROUND a N AERAR SITE WIRING ele o 4 ollo 4 N GROUND NEUTRAL REMOTE LOCKOUT INDICATION REMOTE LOCKOUT RESET NOTE For external fan wiring See Page 29 Section 11 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 28 of 53 SECTION 11 WIRING AND ELECTRICAL INFORMATION 11 10 CTUD External Motor Alternative Wiring amp Optional Thermostat Time Switch Single Phase Motor Three Phase Motor with Load over 7 Amps N 2 3 N L 1 sla Room Room Thermostat Thermostat Yea 1 9 a A iJ Frost B Thermostat Frost Thermostat
31. al Data Tables for the correct gas and model on Page 11 Section 5 4 32 of 53 Regulator Under Cover Plug for Main Safety Gas Valve Gas Outlet 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 11 Section 5 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 12 5 Combustion Testing The only adjustment to alter combustion performance is burner pressure Combustion quality must be tested to prove correct heater operation Incorrect results will indicate faults with the installation or appliance Combustion testing must be carried out with all covers in place The flue gas is sampled in the flue within 1 meter of the heater The values of CO should be between 6 5 to 8 0 for natural gas and 7 0 to 9 1 for LPG dependant upon model The CO will be up to 80 ppm 0 008 dry air free dependant upon model Temperature rise
32. deposits from the screen See Page 15 Section 7 through Page 17 Section 8 Combustion Air Intake Pipe Intake pipe and inlet must be intact Look for obstructions cracks on the pipe gaps in the sealed areas or corrosion The area must be free of dirt and dust Clean and reinstall as required 37 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL Heat Exchanger Gas Line and Shut off Valves Burner Observation Window Flue Blower Scroll Wheel and Motor Inshot Burners and Orifices Direct Spark Igniter Thermostat Suspension Points Silicone Tubing Gas Valve Condensate Drain when installed Ductwork Air Circulation Blower Wall Tag Safety Labels 38 of 53 Make sure there are no cracks Make sure there is no sagging bending or distortion Clean or replace as required Check for gas leaks See Page 19 Section 10 Make sure it is clean and free of cracks or holes Clean and replace as required Compressed air or a vacuum cleaner may be used to clean dust and dirt Clear obstructions even spider webs will cause problems Carefully remove any dust and debris from the burner Replace if there are cracked ceramics excessive carbon residue or erosion of the electrode The electrode gap should be 1 8 3 2 mm There should be no exposed wire or damage to the device or wiring See Page 21 Section 11 Make sure the heater is hanging securely Look
33. e 25 mm air gap to Combustible Material Flue Air Intake Terminal Cover Vertical Option i 4 g Bend Masterflash ue E Horizontal 2 Option Wall Terminal Figure 9 Vertical and Horizontal Flue Termination Type C42 C32 amp Ces Appliances Roof Terminal Model Concentric Flue Diameter 40 60 Cover 100mm 75 115 Cover 130mm Plastic Cup IB HHH Masterflash Manifold Air Intake Vertical Option A 90 Bend 7 Air intake XIS ee Flue s Horizontal A Option Manifold The minimum Max wall thickness gap must be 335 mm positioned at bottom 16 of 53 SECTION 8 AIR SUPPLY 8 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 8 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 16 Figure 8 8 2 1 Heaters Installed Within the Heated Space Where the volume of the heated space is greater than 4 7 m per kilowatt of total rated heat input and the a
34. e 15 3 Gas Vaves SECTION 16 Troubleshooting 16 1 e TTT 16 2 Troubleshooting For Automatic Ignition Burner UL 42 16 3 Troubleshooting for Flame Supervision System 43 16 4 Troubleshooting for Solenoid Valves 000 43 SECTION 17 Removal and Replacement Parts 0 44 17 1 Qas VaVe TT 45 17 2 Burner Compartment eee ee eee ee eee ee eee ee 47 17 3 Ignition Electrode and Flame Probe sese 49 174 Flue Fameen aaia 50 17 5 Pressure Switch eee eee 51 17 6 Ignition Control eee ee eee eee 52 17 7 CTUA Axial Fan Guard Motor Assembly 44 52 17 8 CTUB amp CTUC Centrifugal Fan Guard Motor PASSOUMDIY oi ciel isro eiaa e aR EEE Ea 52 179 Fan Dates icici aneri aor aik 53 2014 Roberts Gordon Europe Limited All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Roberts Gordon Europe Limited Printed in U K TABLE OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Side and Back Panel Label Placement 06 2 Side Panel Label Placement eee eee 3 Installation Clearances and Clearances to Combustible Gs seS iis ain eens 6 Suspension MethodS sese eee eee 13
35. eath injury or property damage For typical suspension See Page 13 Figure 4 The gas or electrical supply lines must not be used to support the heater Do not locate the gas or electrical supply lines directly over the path of the flue products from the heater The heater must be installed in a location that is readily accessible for servicing The heater must be installed in accordance with clearances to combustibles as indicated on the wall tag and in this manual 6 6 Wall Mounting For typical suspension See Page 14 Figure 6 Wall mounted 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 using all mounting holes Screw sizes less than 9 0 mm 3 8 may not be used In order for the wall mounting brackets to adequately carry the weight of the heater it must be installed according to best building practices SECTION 6 HEATER INSTALLATION Figure 4 Suspension Methods S Insure all suspension hardware is torqued to a minimum of 27 Nm 20 ft Ibs Washer He Nut Cone Point Set Pin Support Points Shelf Mounting o l Brackets Existing cabinet screws must be re used 13 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL Figure 6 Wall Shelf Mounting and Suspension Wall Shelf Mounting Wall Suspension Mounting Sh
36. elf Mounting 3 8 Fasteners Brackets Fasten to N l m T Wall Mounting Bracket L l Wall Mounting Bracket Arm Right amp Left 5 16 x 3 1 2 Bolt 5 16 Flat Washer a eh 5 16 Locknut with Nylon Insert ia Torque to 40 in Ib 4 5 Nm Wall Mounting Bracket Diagonal Wall Mounting pee Bracket Vertical Hardware to construct mounting bracket assembly not provided by Roberts Gordon Europe Limited 14 of 53 SECTION 7 FLUE INSTALLATION 7 1 Flue Installation AWARNING Carbon Monoxide Hazard Heaters installed unvented must be interlocked with sufficient building exhaust Heaters must be installed according to the installation manual Failure to follow these instructions can result in death or injury AWARNING Fire Hazard Keep all flammable objects liquids and vapours the minimum required clearances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage AWARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp Failure to follow these instructions can result in injury 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 15 Figure 7 through
37. erts Gordon Europe Limited and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilitate optimum performance and safety Roberts Gordon Europe Limited recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equipment and perform service where necessary using only replacement parts sold and supplied by Roberts Gordon Europe Limited 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 Opening the door exposes live electrical connections and hot components 12 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 30 of 53 12 1 1 Louvres Where fitted the air delivery louvres need to be set during commissioning to give the required air distribution 12 1 2 Electrical Checks All pre commission checks must be carried out before commissioning the heater 1 Check that all site wiring
38. eu siell gas ROBERTS GORDON Open windows DO NOT try to light any appliance DO NOT use electrical switches DO NOT use any telephone in your building Extinguish any open flame Leave the building Immediately call your local gas Tu b u I a r U n it H e ate rs supplier after leaving the building Follow the gas supplier s instructions _ if you cannot reach your gas Installation Commissioning supplier call the Fire Department A WARNING Operation amp Service Manual Model CTU 40 to 115 RSO E Fire Hazard Keep all flammable objects liquids and vapours the minimum required clearances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage Installer A WARNING Improper installation adjustment alteration service Please take the time to read and understand or maintenance can result in death injury or these instructions prior to any installation property damage Read the installation operation Installer must give a copy of this manual to the owner and service manual thoroughly before installing or Owner servicing this equipment Keep this manual in a safe place in order to provide Installation must be done by a registered installer your service technician with necessary information contractor qualified in the installation and service of
39. event fire hazards Caution should be used when running the system near combustibles Combustibles are materials which may catch on fire and include common items such as wood paper rubber fabric etc Maintain clearances to combustibles at all times for safety Clearances around the heater and flue must be as indicated on Page 6 Figure 3 to ensure access for servicing and correct operation If clearances to combustibles are not indicated then installation clearances apply Check the clearances on each burner for the model heater being installed to make sure the product is suitable for your application and the clearances are maintained Read and follow the safety guidelines below e Keep petrol or other combustible materials including flammable objects liquids dust or vapours away from this heater or any other appliance Do not spray aerosols in the vicinity of this appliance s The stated clearances to combustibles represents a surface temperature of 50 C 90 F above room temperature Building materials with a low heat tolerance such as plastics vinyl siding canvas tri ply etc may be subject to degradation at lower temperatures It is the installers responsibility to assure that adjacent materials are protected from degradation Maintain clearances from heat sensitive equipment and workstations Maintain clearances from vehicles parked below the heater SECTION 3 CLEARANCES TO COMBUSTIBLES e Maintain cleara
40. f gas supply to Allow heater to cool Wear protective gear before service heater before service before service during installation operation and service More than one Tubing may still be hot disconnect switch may after operation Edges are sharp be required to disconnect electric from heater Heater must be connected to a propery grounded electrica source Failure to follow these instructions can result in death electric shock injury or property damage WARN NG NOTE 2 Check all gas pipes and pipe joints to A 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 Severe Injury Hazard 14 2 Burner Maintenance Turn off gas and electrical supply before 1 Open the hinged door and remove the burner service compartment cover See Page 47 Section 172 Fan can start automatically at any time 2 Clean any deposits from the main burner which may have formed in the injectors or venturi of Failure to follow these instructions can the burner See Page 47 Section 172 result in severe injury or product damage 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 14 3 Fan Motor Assemb
41. for signs of wear on the suspension materials or ceiling See Page 12 Section 6 Ensure tight secure fit on all pressure fittings at pressure switch burner partition and blower outlet Verify that cap covering pressure regulator adjustment screw is secure and has not been tampered with Verify all wiring connections Flush drain and clear any obstructions Consult an indoor air quality professional for proper cleaning procedures For a complete inspection refer the manufacturers Installation Operation and Service manual If wall tag is present make sure it is legible and accurate Please contact Roberts Gordon Europe Limited or your ROBERTS GORDON independent distributor if you need a wall tag See Page 4 Section 2 1 Product safety signs or labels should be replaced by the product user when they are no longer legible Please contact Roberts Gordon Europe Limited of your ROBERTS GORDON independent distributor to obtain replacement signs or labels See Page 2 Figure 1 through Page 3 Figure 2 SECTION 15 CONVERSION BETWEEN GASES 15 1 General Conversion between gases will require a change of burner injectors and the gas valve re commissioning to the new conditions 15 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 47 Section 172 2 Remove the connection between the gas valve outlet and the man
42. gas fired heating equipment or your gas supplier 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 robertsgordon co uk www rg inc com www combat co uk 2014 Roberts Gordon Europe Limited P N X407UK Rev N 03 14 TABLE OF CONTENTS SECTION 1 Heater Safety cccsscsseeeseeseceeeeeseneeseeeseeeseeees 2 1 1 Manpower Requirement sese eee eee eee eee eee eee 2 1 2 Safety Labels and Their PIacement eee 2 SECTION 2 Installer Responsibility sccsssseeeeeees 4 2 1 Laminated Wall Plate sees sese 4 2 2 Corrosive Chemicals sese eee eee 4 2 3 National Standards and Applicable Regulations 4 SECTION 3 Clearances to Combustibles cecsseeeeees 5 3 1 Required Clearances to Combustibles 0 06 5 SECTION 4 Critical Considerations csecsseseteeeeees 7 41 Ventilation esicccesectititn erst iain Snes 7 4 2 Gas Supply APTE 7 4 3 Electrical Supp sese sees esec 7 CTT 7 SECTION 5 Specifications cccseceseseeteeeeeeseeeeeeeeeeeseens 8 er TTT 8 5 2 CTUB CTUC and CTUD sees 9 5 3 General Technical Data Table seene eee 10 5 4 Technical Data Table see eee eee 11 SECTION 6 Heater Installation c
43. hermostats 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 11 2 3 Remote Frost Thermostat Controls to operate the burner CTU 75 115 connect between terminals 2 amp 3 of the main terminal block CTU 40 60 connect controls between T and Li Locate within the heated space adjacent to the most vulnerable equipment that requires protection See Page 22 Section 11 3 through Page 23 Section 11 4 11 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 T and L CTU 40 60 L amp 1 CTU 75 115 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 21 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 11 3 CTUA Wiring Diagram Models 40 60 GROUND TIME DELAY AXIAL FAN GAS VALVE IGNITION Ww B GROUND GROUND x O N IWLSOWHYA3HL LINT AYVAONOO3S amd AldyNnd amd MOT1AA N34e9 al G L E N L COMBUSTION FAN
44. ifold See Page 45 Section 171 for gas valve removal 3 Remove the manifold from the burner assembly by removing the screws at the top and bottom See Page 47 Section 172 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 15 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 11 Section 5 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 SECTION 15 CONVERSION BETWEEN GASES 39 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL SECTION 16 TROUBLESHOOTING A DANGER Electrical Shock Hazard Disconnect electric before service Heater must be properly grounded Failure to follow these instructions can result in death or electrical shock A WARNING Fire Hazard Explosion Hazard Burn Hazard Cut Pinch Hazard Keep all flammable Turn off gas supply to Allow heater to cool Wear protective gear objects liquids and heater before service before service during installation vapors the minimum operation and service required clearances to Tubing may still be hot combustibles away after operation Edges are sharp from heater
45. ilure to follow these instructions can result in death or electrical shock 11 1 Electrical Supply All heaters need a constant 230 V 50 Hz single phase supply connected to terminals L N amp Earth Polarity L amp 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 IEE and local regulations and be carried out by a qualified electrician 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 External fuse protection must be sized in accordance with electrical load requirements on Page 10 Section 5 3 CTUD heaters must have the external fan or its control connected to Terminal 1 so that the fan run on function at close down operates correctly 11 2 Remote Controls The heater is designed to be operated by controls installed remote from the heater See Page 22 Section 11 3 through Page 23 Section 11 4 11 2 1 Burner Controls Thermostat Controls to operate the burner CTU 75 115 connect between terminals 2 amp 3 of the main terminal block CTU 40 60 connect controls between T and L SECTION 11 WIRING AND ELECTRICAL INFORMATION 11 2 2 Positioning Room T
46. in the installation and service of equipment sold and supplied by Roberts Gordon Europe Limited and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilitate optimum performance and safety Roberts Gordon Europe Limited recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equipment and perform service where necessary using only replacement parts sold and supplied by Roberts Gordon Europe Limited 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 2012 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 www combat co uk Printed i
47. ir 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 e Heaters up to 70 kW heat input 5 0 cm per kW of rated heat input s Heaters above 70 kW heat input 350 cm 2 5 cm per kW of rated heat input above 70 kW SECTION 8 AIR SUPPLY 8 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 8 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 heater 8 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 17 Figure 10 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
48. ly 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 14 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 NOTE 1 After any maintenance or repair work always test fire the heater in accordance with the 14 3 1 For CTUB amp CTUC Centrifugal Fan commissioning instructions on Page 30 Section 12 Models through Page 33 Section 12 9 to ensure all safety l systems are in working order before leaving the CTUB and CTUC models are fitted with thermally protected three speed fans The number of fans can NETEN E Ops ete ne ens nay eee be found on Page 53 Section 179 and the standard mae S peel vag o Pw air flow for each model can be found on Page 10 36 of 53 Section 5 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
49. mal operation of this heater 34 of 53 13 3 Common User Controls 13 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 Part Number All Models 90412100 13 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 8 Section 5 1 or the remote reset if installed on site If control locks out do not make more than three attempts to restart the heater Dangerous fuel mixtures can build up The fault must be traced and repaired by a registered installer or service engineer 13 4 Lighting Instructions 13 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 firing sequence will begin as described on Page 31 Figure 13 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 35 Section 13 3 2 13 4 2 To Turn the Heater Off Set the installed remote controls to the OFF position The burner will turn off
50. mited Design Department for recommendations regarding duct resistance and design Tel 44 0 121 506 7700 Figure 11 Ducting NOTE Duct size will be full size of inlet and outlet All joints between the heater and duct work should be made as air tight as possible Airflow Indicator ae 7 Twice A Dimension uyn A 18 of 53 9 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 9 Section 5 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 18 Section 9 1 and Figure 11 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 Dimension Y Minimum Twice Dimension 7 iin S Ducting Flexible Flange
51. n U S A P N 91040028 Rev C
52. nces from swinging and over head doors overhead cranes vehicle lifts parti tions storage racks hoists building construction etc In locations used for the storage of combustible materials signs must be posted to specify the maximum permissible stacking height to main tain required clearances from the heater to the combustibles Signs must be posted adjacent to the heater thermostat In the absence of a ther mostat signs must be posted in a conspicuous location Consult local Building Inspector Fire Insurance Carrier or other authorities for approval of pro posed installation when there is a possibility of exposure to combustible airborne materials or vapours Hang heater in accordance to the minimum suspension requirements on Page 12 Section 6 and Page 13 Figure 4 through Page 14 Figure 6 e Affix the tag on a wall near the heater 5 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL Figure 3 Installation Clearances and Clearances to Combustibles Installation Clearances Clearances to Combustibles Roof Terminal Terminal 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 The heater must always be installed at least 2 5 m above the floor The flue pipe must have clearance from combustibles by 5 cm If installed at low levels where individuals can come
53. nt A 13 4 15 2 23 3 23 3 High Bun Current J A L a T 88 3300 5500 5500 6400 6400 9400 9400 Sound Pressure Level 59 61 61 62 62 63 63 at3 m NR dB A 59 5 61 5 61 5 61 8 61 8 64 2 64 2 CTUD Duct Heater with No Fan Minimun Air Flow Required m3 h 3300 5500 5500 6400 6400 9400 9400 Pressure Loss Across Heat Exchanger 30 30 30 30 30 30 30 Flue and Alr Intake Flue and Air Intake Size mm 100 100 100 130 130 130 130 Maximum Straight Flue Air Intake m 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 10 of 53 SECTION 5 SPECIFICATIONS 5 4 Technical Data Table Appliance Category II 2H sap CTU 40 CTU 50 CTU 60 CTU 75 CTU 90 CTU 100 CTU 115 Pees cad Input L 479 61 5 70 95 111 119 134 7 Gross CV Btu h x 1000 163 210 239 325 378 406 460 Heat Input kW 43 55 63 86 100 107 121 Net CV Btu h x 1000 147 189 215 292 341 365 414 Approximate kW 40 51 58 79 92 98 111 Heat Output Btu h x 1000 135 173 197 267 312 334 379 Thermostat Limit Thermodisc 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 mbar 9 5 9 7 9 7 6 1 6 0 6 2 6 3
54. of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL SECTION 17 REMOVAL AND REPLACEMENT PARTS ADANGER A WARNING Electrical Shock Hazard Explosion Hazard Fire Hazard Carbon Monoxide Hazard Use only genuine ROBERTS GORDON replacement parts per this installation operation and service manual Failure to follow these instructions can result in death electric shock injury or property damage See warnings and important information before removing or replacing parts After any maintenance or repair work always test fire the heater in accordance with the commissioning instructions on Page 30 Section 12 to help 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 40 Section 16 through Page 43 Section 16 4 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 8 Section 5 The entire heater enclosure containing the burners and gas controls is a sealed compartment Ensure proper sealing and replace gaskets as needed Part Number 92700022 Filler Panel RO56A 44 of 53 SECTION 17 REMOVAL AND REPLACEMENT PARTS 17 1 Gas Valve Remove the gas supply pipe at the heater inlet 17 1 1 Models 40 60 Pressure Ignition switch Control Time Delay Axial Fan Harness with EMC Filter 45
55. of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 17 1 2 Models 75 115 Pressure Ignition Switch Control U U c B en ee ee ees ees 9 Time Delay Axial Fan Harness with EMC Filter 904398XX Gas Valve VR4605 Models 75 115 90033404 17 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 32 Section 12 4 2 IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVES SPECIFIED FOR EACH MODEL TYPE ARE USED WHEN REPLACING THESE CONTROLS 46 of 53 SECTION 17 REMOVAL AND REPLACEMENT PARTS 17 2 Burner Compartment Before burner removal remove the 10 screws holding the filler panel on and remove the filler panel Burner Assembly 17 2 1 Burner Compartment without Filler Panel Ignition Electrode Manifold Orifice Inshot Burners Note Burner assembly must be removed to service injectors manifold or burners 47 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL 17 2 2 Burner Assembly Remove 4 screws to remove manifold Screws Flame Probe e Unscrew Orifice 4 m j N WA V Ignition Electrode Inshot Burners 48 of 53 S
56. 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 of 53 COMBAT CTU UNIT HEATERS 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 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 domestic indoor spaces Do not install in domestic spaces These instructions the layout drawing local codes and applicable standards that apply to gas piping electrical wiring venting etc must be thoroughly understood before proceeding with the installation Protective gear is to be worn during installation operation and service Thin sheet metal parts of the heater and the various venting components have sharp edges To prevent injury the use of work gloves is recommended Before installation check that the local distribution conditions nature of gas and pressure and adjustment of
57. ontinue to cool heat exchanger until the fan l S thermostat switches off Keep all flammable objects liquids and vapors the required clearances to combustibles away from IF THE HEATER WILL NOT OPERATE TO ENSURE YOUR SAFETY heater FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER Some objects can catch fire or explode when placed 1 Set the thermostat to off or the lowest setting close to heater 2 Turn off electric power to the heater 3 Turn off the manual gas valve in the heater supply line f z z 3 4 Call your registered installer contractor qualified in the Failure to follow these instructions can result in installation and service of gas fired heating equipment death injury or property damage Installation Clearances Roof Terminal Clearances to Combustibles 50 cm gt Wall Terminal E 1 7 80 cm is necessary to service heater Heaters may be mounted at a higher level if destratification fans and or turn down nozzles are installed Roberts Gordon Europe Limited Fax 44 0 121 506 7701 Unit A Kings Hill Business Park Service Telephone 44 0 121 506 7709 Darlaston Road Wednesbury Service Fax 44 0 121 506 7702 West Midlands WS10 7SH UK E mail uksales rg inc com Telephone 44 0 121 506 7700 E mail export rg inc com Installation Code and Annual Inspections All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified
58. sscsseseeseeeereeseeeeee 12 6 1 General eee 12 6 2 Basic Information sse esse eee e eee eee eee eee eee 12 6 3 Location and Suspension eee eee eee ee 12 6 4 Handlinga nenir eae enn aban 12 6 5 Suspension and Shelf Mounting sese ee eee ee 12 6 6 Wall Mounting sss sss sees eee eee eee eee eee eee 12 SECTION 7 Flue Installation sss sesseeseesseeseeseessees resse rese 15 7 1 Flue Installation sese eee eee eee eee eee 15 7 2 Type Ca Cass amp Ces Appliance see 15 7 3 Type Boo ApOIIanGe sese eee 15 SECTION 8 Air Supply 22 c scescccsesresecesceeseseesneesseerenseeenes 17 8 1 Room Sealed installation sese eee ee eee 17 8 2 Open Flued lnstallaion sese 17 8 3 Building Ventilation eee eee eee eee eee 17 8 4 Isolated Equipment BHoOonms sese sees eee eee eee ee 17 SECTION 9 Optional Heater Conigurations ss ssssess esse 18 9 1 Distribution Duct Work for CTUB CTUC and CTUD NI 18 SECTION 10 Gas Pipe Work ccssecesesseesseesseenseeenseeneeee 19 10 1 CONNECTIONS sees eee ee eee eee eee 19 SECTION 11 Wiring and Electrical Information 6 21 11 1 Electrical Supply eee ee eee ee eee 21 11 2 Remote Controls sese ee eee ee eee 21 11 3 CTUA Wiring Diagram Models 40 60 sese 22 11 4 CTUA Wiring Diagram Models 75 115 23 11 5 CTUB C Wiring Diagram Models 401 se 24 11 6 CTUB C Wiring Diagram Models 50 60 00 25 11 7 CTUB C Wiring Diagram Models 7
59. stat Fan Pressure P l Switch An Neon Fa Ignition EK 05 Valve a Flame Sensing Lockout Alarm Signal l n is zZ o Q E i 2 Q Burner Neon D Tp Tp 30 sec 30 sec 40 sec max Interruption of main Burner Lockout 11 sec typical flame sensing signal received after 3 ignition trial failures NOTE If the heater operates for more than 24 hours continuously the ignition module will automatically recycle the burner to ensure that all safety functions are still in working condition 31 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL Figure 14 Gas Valve for Heater Models 40 60 On Off solenoid valve EV1 On Off solenoid valve EV2 Outlet Pressure Test Point SS On Off Solenoid valves NS EVT and EV2 Ternminals Inlet Pressure Test Gas Inlet Main Gas Valve Inlet Pressure Gas Inlet b Outlet Pressure 12 4 2 Commissioning the Gas Valves all gases 12 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 nic
60. 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 regulations To safely and adequately install heater using materials that support heater weight To ensure the heater is placed in an approved application 2 1 Laminated Wall Plate A laminated wall plate is available for the heater as a permanent reminder of the safety instructions and the importance of the required clearances to combustibles Affix theplate by peeling off the backing of the adhesive strips on the rear surface and position the plate on a wall near the heater e g thermostat or ROBERTS GORDON Controller A copy of the wall plate P N 91040028 is illustrated on the back cover Know your model number and installed configuration Model number and installed configuration are found on the heater and in the Installation Operation and Service Manual 4 of 53 2 2 Corrosive Chemicals A CAUTION Product Damage Hazard Do not use heater in area containing corrosive chemicals Refer to appropriate Material Safety Data Sheets MSDS Failure to follow these instructions can result in product damage Roberts Gordon Europe Limited 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
61. ted 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 6 2 Basic Information CTU heaters have automatic ignition burners for ON OFF operation only 6 3 Location and Suspension All models e Must be installed indoors s Must be installed in a level position s May be mounted on a shelf of non combustible material See Page 13 Figure 5 Page 14 Fig ure 6 and the Dimension Data Tables on Page 8 Section 5 1 and Page 9 Section 5 2 for support points May be suspended from above See Page 13 Figure 4 or from wall brackets of sufficient strength to support the heater as listed in the Dimension Data Tables on Page 8 Section 5 1 and Page 9 Section 5 2 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 6 4 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 12 of 53 6 5 Suspension and Shelf Mounting AWARNING Crush Hazard Use 10 mm steel drop rod minimum Failure of the supports can result in d
62. ted to the service pipe by the gas supply company An existing meter should be checked preferably by the gas supplier 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 regulations Pipe work from the meter to the heater s must be of adequate size 10 1 Connections Connect the heater to the gas supply ensuring that the final connections are as follows e Gas supply pipe work is run in medium or heavy gauge tubing in compliance with local and national regulations 19 of 53 COMBAT CTU UNIT HEATERS INSTALLATION OPERATION AND SERVICE MANUAL Figure 12 Gas Connection with Stainless Steel Flex Connector 20 of 53 A CAUTION Product Damage Hazard Hold gas nipple securely with pipe wrench when attaching gas hose Failure to follow these instructions can result in product damage Gas Isolating Valve Do not twist flexible gas connector Ensure all joints are gas tight Option A Stainless Steel Flex Gas Connector Option B Medium or Heavy Gauge Tubing Gas Connector S t Union Connection Drip Leg vai Cap SECTION 11 WIRING AND ELECTRICAL INFORMATION A DANGER Electrical Shock Hazard Disconnect electric before service Heater must be properly grounded Fa
63. the appliance are compatible Figure 1 Side and Back Panel Label Placement FRONT VIEW N liui y EAA A n TI f l by ROBERTS GORDON The heater must be applied and operated under the general concepts of reasonable use and installed using best business practices This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do no play with the appliance For additional copies of the Installation Operation and Service Manual please contact Roberts Gordon Europe Limited 1 1 Manpower Requirements To prevent personal injury and damage to the heater two persons will be required for installation 1 2 Safety Labels and Their Placement Product safety signs or labels should be replaced by the product user when they are no longer legible Contact Roberts Gordon Europe Limited for obtaining replacement signs or labels See Page 2 Figure 1 through Page 3 Figure 2 REAR VIEW ne Wiy LOCKOUT RESET Lockout Reset Labe Logo Label MOa WvuoviG _NOLLOANNOO Description Logo Label Lockout Reset Label 91038303 Address Label 91040006 Rating Plate Label 91

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