Roberts Gorden Compact Tubular Unit Heaters CTCU 11 User's Manual
Contents
1. 18 11 1 User 18 11 2 Heater 18 11 3 Common User Controls 18 11 4 Lighting Instructions 18 11 5 Simple Fault Finding 19 SECTION 12 Servicing 20 12 1 Servicing Instructions 20 12 2 Burner Maintenance 20 12 3 Fan Motor Assembly Maintenance 20 12 4 Heat Exchanger 20 12 5 Gas Control Valve 20 12 6 Flue Fari iie HI india tdt 20 O 2006 Roberts Gordon LLC All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Roberts Gordon LLC Printed in U S A TABLE OF FIGURES Figure 1 Installation Clearances and Clearances to Combustibles ito iaa dida 4 Figure 2 Suspension 7 Figure 3 Shelf Mounting and Hanging Suspe2. 28 Air Intake Adapter Intake amp Exhaust Covers 15 4 Flue Fan Vertical Installation Mounting Plate to Flue Fan fixing screws Air Intake Adapter Mounting Plate to Vent Box fixing screws AN Intake amp Exhaust Covers gt Mounting Plate to Vent Box fixing screws Gaskets Vent Box SECTION 15 REMOVAL AND REPLACEMENT PARTS To remove the fan remove 3 screws securing the fan and mounting plate to the vent box To remove the fan from the mounting plate remove the 4 screws 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 Rotate the fan mounting plate and gasket clockwise until the flue adapter lines up with the top hole Secure with 3 screws Remove the flexible duct from the air intake adapter on the back Remove the air intake adapter from the back of the heater and install in the appropriate hole on top Reconnect the flexible duct Install intake and exhaust covers over the back holes Ensure sealed joints Ensure mounting plate orifice is clear and not obstructed MODEL CTCU 7 CTCU 11 CTCU 15 CTCU 22 CTCU 27 CTCU 32 Fasco Fasco Fasco Torin Sit Controls Sit Controls Flue Fan 7021 11767 7021 11768 7021 11769 S6818 P1210838 P1210838 RG P N 90710470 9071047
3. ar 14 6 WG Min 25 mbar 10 in WG Max 45 mbar 18 in WG Alternative where permitted 50 mbar 20 in WG Min 42 5 bar 17 in WG Max 57 5 mbar 23 in WG Burner Pressure mbar 25 6 29 4 29 4 28 6 29 9 29 9 m h 0 3 0 5 0 7 1 1 2 1 4 Gas Rate kg h 0 16 0 25 0 34 0 51 61 71 LPG Butane G30 Data Inlet Pressure 29 mbar 11 4 in WG Min 20 mbar 7 8 in WG Max 35 mbar 13 8 WG Burner Pressure mbar 19 2 21 9 22 9 21 4 21 4 22 4 m h 0 2 0 4 0 5 0 8 9 1 1 Gas Rate kg h 0 09 0 14 0 19 0 29 34 42 Gas rates corrected to standard conditions 1013 25 mbar 15 C 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 Crush Hazard Use 10 mm steel drop rod minimum Failure of the supports can result in death injury or property damage For typical suspension See Page 7 Figure 2 Figure 2 Suspension Methods SECTION 5 HEATER INSTALLATION 5 3 Wall Mounting For typical suspension See Page 8 Figure 3 Heaters blowing parallel to the wall can only be installed with the service door away from the wall The wall mounting brackets must be a
4. y Heaters may be mounted at a higher level if destratification fans are installed A WARNING Fire Hazard Some objects can catch fire or explode when placed close to heater Keep all flammable objects liquids and vapors the required clearances to combustibles away from heater Failure to follow these instructions can result in death injury or property damage Clearances to Combustibles 80 cm is necessary to service heater Roberts Gordon LLC 1250 William Street P O Box 44 Buffalo NY 14240 0044 USA Telephone 716 852 4400 Fax 716 852 0854 Toll Free 800 828 7450 Roberts Gordon Europe Limited Oxford Street Bilston West Midlands WV14 7EG UK Telephone D 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 Installation Code and Annual Inspections All installations and service of ROBERTS GORDON products must be performed by a contractor qualified in the installation and service of products sold and supplied by Roberts Gordon and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service and operation of the equipment To help facilitate optimum performance and safety Roberts Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON products and perform
5. meter must be inspected tested for soundness and purged in accordance with local and national codes Ensure that the air is fully purged from the heater inlet pipe up to the main gas valve inlet test nipple 10 1 4 Mechanical Checks 1 Check that the fan is free to run and delivery louvres are turned to give required air deflection 2 Check that the flue and air intake for room sealed is installed in accordance with these instructions and local regulations NOTE The limit thermostat is sealed at the factory and is not adjustable 10 2 Begin Commissioning 10 2 1 Before Operating the Heater To ensure that all the controls are in safe working order operate the heater for the first time with the isolating gas valve turned off 1 Turn off the isolating gas valve 2 Using the installed external control turn on the burner The automatic sequence will now begin as described on Page 16 Figure 9 There will be no ignition of the burner and lockout will occur which proves the controls are operating correctly 15 COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL Figure 9 Automatic Burner Control Box Sequence Burner sequence for Honeywell S4565C Supply 230 V o o MAA Flue Fan F e NO 30 Sec Purge Pressure Switch C Se NC ts 10 seconds Ignition Spark QX Suncasvave CY 0j Dar ER pu Flame Signal Et i Purge time begins at pressure
6. 10 23 COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL 14 3 Troubleshooting for Flame Supervision System To measure flame current connect a O 50 yA 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 uA DC flame current Use Section 14 1 to trace the fault Is the connecting lead damaged Is the flame probe damaged or touching earthed components Is there a current flowing in the flame probe circuit with no flame present Repair or replace as Yes necessary Is inlet burner gas pressure correct Is live and neutral polarity correct Is flame probe circuit correct Does lockout occur when there is a flame present Control box faulty Replace with correct type Repair or replace as necessary If problems persist contact Roberts Gordon Ltd at www rg inc com Heater Operating TROUBLESHOOT ENDS NOTE Minimum flame probe current 1 uA DC Typical flame probe current 3 5 pA DC 24 SECTION 14 TROUBLESHOOTING 14 4 Troubleshooting for Solenoid Valves START Is gas pressure at inlet of the valve correct for gas type Fault elsewhere Note pressure found Does gas pressure at outlet Valve or ignition control of the valve ris
7. The final connection to the heater should be made by flexible cable or conduit to the 7 pole plug using 1 mm cable on all models A WARNING Electrical Shock Hazard Disconnect electrical power before servicing Failure to follow these instructions can result in death or electrical shock 9 2 Remote Controls The heater is designed to be operated by controls installed remote from the heater See Page 14 Section 9 3 9 2 1 Burner Controls Thermostat Controls to operate the burner must be connected between L and 2 9 2 2 Positioning Room Thermostats or ROBERTS GORDON Control A room thermostat or ROBERTS GORDON control should be mounted on a wall or column at a height of approximately 1 5 metres from the floor to measure the ambient temperature It should be clear of both cold draughts and the direct path of warm air from the heater 9 2 3 Remote Frost Thermostat When required connect to L and T parallel to the room thermostat Locate within the heated space adjacent to the most vulnerable equipment that requires protection See Page 14 Section 9 3 9 2 4 Remote Fan Controls The fan will operate automatically providing there is a constant 230 V supply A switch or control wired between L 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 im
8. can come in contact with hot heat exchanger components adequate guarding must be provided All distances are minimum clearance requirements for service access air flow and safety SECTION 4 SPECIFICATIONS 4 1 CTCUA All Models Mountin Holes 140 for 27 32 Dimension Data CTCUA All Models Air Intake Flue onModel22 SECTION 4 SPECIFICATIONS 4 x M10 Captive Nuts Provided Air Intake Optional Position Flue Optional Position End View de Air Intake Electrical Connection Lockout Reset Gas Supply N o I Model CTCU 7 CTCU 11 CTCU 15 CTCU 2 CTCU 27 32 A in E un on E an s E B Mounting Hole Spacing in oa 04 d 52 d 52 202 C Centre of Flue Top Option E E E E B D Centre of Flue in en 1 E Weight kg 28 30 5 38 5 41 523 COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL 4 2 General Technical Data Table All Models Model CTCU 7 CTCU 11 CTCU 15 CTCU 22 CTCU 27 32 CTCUA Axial Fans Total Electrical Load 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 m h 1120 1220 2710 2750 4474 NR 31 35 39 42 42 Sound
9. intakes must be adequately supported so that the heater does not bear the weight of the pipes For flue termination See Page 9 Figure 5 through Page 10 Figure 7 6 3 Type Ci amp Ca Room Sealed The heaters are designed to be installed as room sealed appliances The flue and air intake are run as separate pipes to the special concentric wall or roof terminal See Page 10 Figure 7 The wire mesh inside the fresh air adapter on the heater must be removed prior to installation 6 4 Type Appliance The flue must be fitted with a low resistance terminal See Page 9 Figure 5 through Page 10 Figure 6 COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL Figure 6 Vertical and Horizontal Flue Termination Type B Appliance Roof Terminal Masterflash Vertical Option Masterflash ij A Horizontal E _ Option Wall Terminal Figure 7 Vertical and Horizontal Flue Termination Type C12 Cs Appliances Roof Terminal Plastic Cup Masterflash Manifold Air Intake gt Vertical Option Remove Internal Horizontal Wall Wire Mesh d Option Plate Flue Air Intake t Wall Remove Internal Manifold Terminal Wire Mesh 10 SECTION 7 AIR SUPPLY SECTION 7 AIR SUPPLY 7 1 Room Sealed Installation When installed as a room sealed heater the air for
10. 0 90710470 90710460 90710460 90710460 Air Plate mm Y 35 44 57 64 109 2 109 2 in 1 38 1 75 2 25 2 50 4 3 4 3 RG P N 11111210 11112210 11113210 11114210 11115210 11115210 IT IS IMPORTANT THAT ONLY THE CORRECT FLUE FAN SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS Carry out a commission after working on or changing a flue fan See Page 18 Section 11 29 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 A WARNING Carbon Monoxide Hazard Use correct pressure switch specified for each model Use of incorrect pressure switch could cause unsafe condition Failure to follow these instructions can result in death or serious injury Carry out a commission after working on or changing a pressure switch See Page 15 Section 10 Pressure Switch CTCU 7 CTCU 11 CTCU 15 CTCU 22 CTCU 27 CTCU 32 RG P N 90439812 90439812 90439812 90439803 90439803 90439803 Colour Code orange orange orange grey grey grey Set Point mbar 0 45 0 45 0 45 1 02 1 02 1 02 in wc 0 18 0 18 0 18 0 41 041 041 30 15 6 Ignition Control The control plugs onto the gas valve Pull out 12 pin electrical connection Pull out ignition cable and flam
11. 7 5 3 Wall Mounting 7 SECTION 6 Flue Installation 9 6 1 Changing Flue and Air Intake Orientation 9 6 2 Flue Installation 9 6 3 Type Cz amp Coo Appliance 9 6 4 Type B gt 9 SECTION 7 Air Supply u 11 7 1 Room Sealed Installation 11 7 2 Open Flued Installation 11 7 3 Building Ventilation a 11 SECTION 8 Gas Piping u u 12 8 1 Connections 12 SECTION 9 Wiring and Electrical Information 13 9 1 Electrical Supply a 13 9 2 Remote Controls eese 13 9 3 CTCUA Wiring Diagram Models 7 32 14 SECTION 10 Commissioning 15 10 1 Pre Commission Checks 15 10 2 Begin Commissioning 15 10 3 Complete the Commissioning 17 SECTION 11 User Instructions
12. CU 11 CTCU 15 CTCU 22 CTCU 27 CTCU 32 Injector Quantity 2 3 4 5 6 7 Natural Gas G20 Injector size mm Y 1 78 1 85 1 85 2 06 2 057 2 057 in 0 070 0 073 0 073 0 081 0 081 0 081 Marking 50 49 49 46 46 46 RG P N 91930050 91930049 91930049 91930046 91930046 91930046 Natural Gas G25 Injector size mm 1 99 2 06 2 06 2 26 2 261 2 261 in 0 0785 0 081 0 081 0 089 0 089 0 089 Marking 47 46 46 43 43 43 RG P N 91930047 91930046 91930046 91930043 91930043 91930043 LPG Propane G31 and LPG Butane G30 Injector size mm 1 18 1 18 1 18 1 25 1 25 1 25 in 0 0465 0 0465 0 0465 0 049 0 049 0 049 Marking 56 56 56 1 25 1 25 1 25 RG P N 91930056 91930056 91930056 91930125 91930125 91930125 27 COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL 15 3 Ignition Electrode and Flame Probe Limit Thermostat 22 RD Fan Thermostat 4 ph Li f cp aa Ignition Electrode yo Burners Burner Compartment Front Views To replace the ignition electrode or flame probe remove the electrical lead and screw Pull out from mounting Refit in reverse ensuring that the gap to burner is as shown in the front view of the burner compartment Description Part Number Spark Electrode 90427411 Automatic Ignition Flame Probe 90439300 Burners 92000002 Fan Thermostat 90412102 Limit Thermostat 90412100
13. 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 10 3 Complete the Commissioning Ensure that all covers are fitted correctly and all test points are properly sealed 10 3 1 Instruction to the User Explain the controls of the heater to the user including how to turn it on and off using the controls fitted on site Give this manual to the user Ensure that the user is shown and understands the importance of maintaining clearances to combustibles and the user instructions on Page 18 Section 11 through Page 19 Section 11 5 and all warnings defined in this manual 17 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 ResetSee Page 18 Section 11 3 2 WARNING Electrical Shock Hazard Disconnect electrical power before servicing Failure to follow these instructions can result in death or electrical shock 11 2 Heater Operation When the heater has been switched on by the remote controls installed on site the main burner will automatic
14. N BETWEEN GASES 21 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 amp electrical supplies on Turn on supplies Is Red lockout warning light on Use 14 2 to test burner Does the fan run Use 14 5 to test fan With external controls on does the burner continue through the heating cycle The limit thermostat has tripped See Section 11 3 2 Has burner Locked Out No Replace limit thermostat Use 14 2 to test burner Replace axial fan If problems persist contact Roberts Gordon Ltd at Tel 44 0 1902 498733 www rg inc com Heater Operating TROUBLESHOOT ENDS No For your safety and optimum heater performance use only ROBERTS GORDON replacement parts Conduct Commissioning procedure as shown on Page 15 Section 10 22 SECTION 14 TROUBLESHOOTING 14 2 Troubleshooting For Automatic Ignition Burner Systems Start Are gas amp electrical supplies on Turn on supplies Are external controls on Turn on controls Press in lockout reset button o
15. Pressure Level at3 m dB A 37 41 45 48 48 Flue and Alr Intake Flue and Air Intake Size mm Y 80 80 80 80 100 Maximum Straight Flue Air Intake m 2 5 4 5 5 5 Electrical load at 230 V 50 Hz measured by calculating from total run current of appliance Do not exceed the maximum length of flue stated or heater may not operate properly Reduce the maximum length stated by 1 m for each 90 bend installed If minimum air flow requirements are not met then temperature limit devices will shut down the heater 4 3 Technical Data Table All Models Appliance Category II H 3B P Model CTCU 7 CTCU 11 CTCU 15 CTCU 22 CTCU 27 CTCU 32 Heat Input kW 8 5 13 4 18 3 275 33 38 5 Gross CV Btu h x 1000 29 46 62 94 113 131 Heat Input kW 7 7 12 1 16 5 24 8 29 7 34 7 Net CV Btu h x 1000 26 41 56 85 101 118 Approximate kW 71 11 1 15 1 23 27 2 31 7 Heat Output Btu h x 1000 24 38 52 78 93 108 Natural Gas G20 Data Inlet Pressure 20 mbar 7 8 in WG Min 17 mbar 6 8 in WG Max 25 mbar 10 in WG Burner Pressure mbar 9 5 9 5 9 5 9 5 9 0 9 0 m h 0 8 13 1 7 2 6 3 1 3 6 Gas Rate ft8 h 29 45 62 93 110 127 Natural Gas G25 Data Inlet Pressure 25 mbar 10 in WG Min 20 mbar 7 8 in WG Max 30 mbar 12 in WG Burner Pressure mbar 9 0 9 0 9 5 9 2 9 2 9 3 m h 0 9 15 2 0 3 3 6 4 2 Gas Rate 33 52 72 108 127 148 LPG Propane G31 Data Inlet Pressure 37 mb
16. ally turn on The burner control box will control the safe ignition of the flame All heaters require a constant gas and electricity supply which must not be interrupted during the normal operation of this heater Figure 11 Heater Operating Sequence ON CLOSE THERMOSTAT DOWN L CALL FOR i BURNER EA RUN ON M 2 3 MINUTES RUN ON B gt FAN Ll pO 11 3 Common User Controls 11 3 1 Fan Thermostat The fan thermostat is located inside the access door at the top of the heater See Page 28 Section 15 3 This control ensures the heater does not blow cold air in the normal heating cycle 11 3 2 Limit Thermostat The limit thermostat is located inside the access door of the heater See Page 28 Section 15 3 This control protects the heat exchanger against overheating 18 Press to reset These are hand reset devices to give further protection against fan failure NOTE To reset the heat exchanger must be cool Description Part Number Limit Thermostat 90412100 WARNING Explosion Hazard If control locks out do not make more than 3 attempts to restart the heater Dangerous gas mixtures can build up The fault must be traced and repaired by a registered installer or service engineer Failure to follow these instructions can result in death injury or property damage 11 3 3 Burner Lockout Reset Button The red warning light on the back of the heater will illu
17. combustion is drawn in from outside the building It is important to ensure that there is adequate ventilation to provide air for the distribution fan 7 2 Open Flued Installation It is important to ensure that there is adequate air supply at all times for both combustion and heating requirements in accordance with local and national codes 7 2 1 Heaters Installed Within the Heated Space Where the volume of the heated space is greater than 4 7 m per kilowatt of total rated heat input and the air change rate is at least 0 5 h additional high and low level ventilation will not be required For a building having an air change rate less than 0 5 h ventilation will be necessary in accordance with local and national codes Ventilation direct to outside must be provided as follows Heaters up to 70 kW heat input 5 0 cm per kW of rated heat input 7 3 Building Ventilation Where ventilation is required air must be taken from an outside point where it is not likely to be contaminated or obstructed Where natural ventilation is used suitable ventilation with outside air at low level must be provided in accordance with Section 72 1 and local and national codes Where mechanical ventilation is used extract rate must be 5 10 less than the inlet rate The mechanical ventilation must be interlocked with the burner on the CTCU heater 11 COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL SECTION 8 GAS PIPING 8 1 Co
18. connect the electrical connections and test operation 31 Attach this information to the wall near the ROBERTS GORDON heater S 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 immediately but fans will continue to cool heat exchanger until the fan thermostat switches off IFTHE HEATER WILL NOT OPERATE TO ENSURE YOUR SAFETY FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER 1 Set the thermostat to off or the lowest setting 2 Turn off electric power to the heater 3 Turn off the manual gas valve in the heater supply line 4 Call your registered installer contractor qualified in the installation and service of gas fired heating equipment Installation Clearances Roof Terminal a Wall Terminal
19. d NOTE 3 Inspect all suspended components and hardware Insure that they are in good condition properly tightened and corrosion free 12 2 Burner Maintenance 1 Open the door and remove the burner compart ment cover See Page 27 Section 15 2 20 2 Clean any deposits from the main burner which may have formed in the injectors or venturi of the burner See Page 27 Section 15 2 3 Remove the ignition electrode and flame probe Check condition of ignition electrode and flame probe Clean off any deposits which may have been formed check condition of ceramic insulators Replace as necessary 12 3 Fan Motor Assembly Maintenance The main fan bearings are permanently sealed and do not need lubrication Before cleaning turn off gas and electrical supply Remove the fan and use a small brush or duster to clean the fan blades from each side Replace fan when done 12 4 Heat Exchanger Maintenance The heat exchanger will remain clean unless a problem has developed with combustion Inspectthe heat exchanger Look for signs of overheating at the front tubes which may indicate burner over firing or persistently low air flows 12 5 Gas Control Valve Maintenance No regular maintenance is required on this device To change gas control valves See Page 26 Step 15 1 and Page 30 Section 15 5 Do not repair or disassemble on site Replace faulty gas valves with genuine ROBERTS GORDON replacement parts 12 6 Flue Fan The fl
20. e flue Each heater must be fitted with an individual and correctly sized sealed flue system 3 2 Location and Suspension See Page 9 Section 6 All models No other appliance may be connected to the flue e Must be installed indoors For room sealed installation the air intake must be the same size sealed system and the flue air intake must terminate at an approved concentric wall or roof terminal Must be installed in a level position with horizon tal or vertical discharge May be mounted on a shelf of non combustible material See Page 5 Section 4 and Page 7 Figure 2 for support points May be suspended from above See Page 7 Fig ure 2 or from wall brackets of sufficient strength to support the heater as listed in the Dimension Data Table on Page 5 Section 4 1 Drop rods must be a minimum of 10 mm diameter mild steel Four suspension points M10 nuts are located on top and back side of the heater Must be installed in a manner which allows access to all serviceable components 3 3 Minimum Required Installation Clearances Clearances around the heater and flue must be as indicated on Page 4 Figure 1 Page 9 Figure 5 through Page 10 Figure 7 to ensure access for servicing and correct operation 3 4 Clearances to Combustibles Clearances must be as indicated on Page 4 Figure 1 If clearances to combustibles are not indicated then installation clearances apply 3 5 Ventilation It is important to ensure that t
21. e 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 A WARNING Electrical Shock Hazard Use extreme caution while commissioning Failure to follow these instructions can result in death or electrical shock 10 1 Pre Commission Checks All pre commission checks must be carried out before lighting the heater Ensure that the heater and all controls are suitable for the gas pressure and electrical supply to which they are to be connected 10 1 1 Louvres Where fitted the air delivery louvres need to be set during commissioning to give the required air distribution optional vertical louvres WARNING Cut Hazard Turn off gas and electrical supply before maintenance Fan can start automatically at any time Failure to follow these instructions can result in severe injury or product damage 10 1 2 Electrical Checks All pre commission checks must be carried out before commissioning the heater SECTION 10 COMMISSIONING 1 Check that all site wiring is connected in accordance with the appropriate wiring diagram on Page 14 Section 9 3 2 Check the correct fuse size is fitted See Page 13 Section 9 1 10 1 3 Gas Supply All aspects of the gas installation including the gas
22. e 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 7 CTCUA Axial Fan Guard Motor Assembly The axial fan unit for the CTCUA heater is supplied completely assembled and balanced 15 7 1 Fan Removal and Replacement Remove the screws and washers Part Number Description Axial Fan CTCU 7 11111910 Axial Fan CTCU 11 Axial Fan CTCU 15 11111911 11111920 Axial Fan CTCU 22 11111921 Axial Fan CTCU 27 32 11111922 15 7 2 To Replace the Fan Assembly To replace the fan assembly reverse the procedure shown above Fit rubber washers to the guard mountings to reduce vibration Check that the fan blades are free to rotate before turning on the power to the fan e Strictly comply with the colour code of the fan wires to ensure correct operation See Page 14 Section 9 3 wiring diagram Use only genuine ROBERTS GORDON replacement parts SECTION 15 REMOVAL AND REPLACEMENT PARTS 15 8 Fan and Limit Thermostats 15 8 1 Removal and Replacement 1 Pull off the electrical connections to the thermostat 2 Unscrew the two screws securing the thermostat 3 Fit a new thermostat with two screws ensuring that the correct temperature setting and type are selected See Page 6 Section 4 3 4 Re
23. e when faulty Replace with valve turns on one of correct type Does gas pressure at outlet of valve return to zero or lower when valve turns off Valve faulty Replace with one of correct type If problems persist contact Valve Operating Roberts Gordon Ltd at TROUBLESHOOT ENDS Tel 44 0 1902 498733 www rg inc com 14 5 Troubleshooting for Main Fan START Does fan run automatically Is power supply 230 V at terminals T1 to N Is there 230 V between Replace fan terminals L1 and N delay thermostat Yes Fan motor faulty Replace with correct type Does fan turn on and off while burner is firing Yes continously Replace fan delay thermostat If problems persist contact Roberts Gordon Ltd at Tel 44 0 1902 498733 www rg inc com Fan Operating TROUBLESHOOT ENDS For your safety and optimum heater performance use only genuine ROBERTS GORDON replacement parts Conduct Commissioning procedure as shown on Page 15 Section 10 25 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 heate
24. gas fired heating equipment 11 5 1 Simple Fault Finding Burner Faults If the burner fails to ignite for any reason it will go to lockout This will be indicated by the red light on the back of the heater or at the remote indicator if fitted 1 Press in and release the lockout reset button If a remote reset is not fitted a reset button is on the back of the heater See Page 5 Section 4 1 Lockout should not occur during normal operation of the heater and indicates there is a fault condition which must be corrected SECTION 11 USER INSTRUCTIONS FOR YOUR SAFETY If you smell gas Open windows DO NOT try to light any appliance DO NOT use electrical switches DO NOT use any telephone in your building Leave the building 6 Immediately call your local gas supplier after leaving the building Follow the gas supplier s instructions If you cannot reach your gas supplier call the Fire Department WARNING Fire Hazard Do not store or use petrol or other flammable vapours and liquids in the vicinity of this or any other appliance Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage 19 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 annuall
25. gas supplier Roberts Gordon Europe Limited Oxford Street Bilston West Midlands WV14 7EG UK Telephone 44 0 1902 494425 Fax 44 0 1902 403200 Service Telephone 44 0 1902 498733 Qualified for Service Fax 44 0 1902 401464 ae E mail uksales rg inc com i E mail export rg inc com Www rg inc com Quality in Any Language O Copyright 2006 Roberts Gordon LLC P N 111100UK RevB 10 06 TABLE OF CONTENTS SECTION 1 Heater Safety 2 SECTION 13 Conversion Between Gases 21 SECTION 2 Installer Responsibility 2 13 1 G n ra u een al 21 2 1 Clearances to Combustibles 2 13 2 Burner Conversion sese 21 2 2 Corrosive Chemicals a 2 13 3 Gas Valves uuu di di n e eine ve 21 2 3 National Standards and Applicable Codes 2 SECTION 14 Troubleshooting 22 SECTION 3 Critical Considerations 3 14 1 General sese 22 3 1 Basic Information 3 14 2 Troubleshooting For Automatic Ignition 3 2 Location and Suspension 3 Burner Systems a 23 3 3 Minimum Required Installation Clearances 3 14 3 Trouble
26. here is adequate air circulation around the heater to supply air for combustion ventilation and distribution in accordance with local and national codes 3 6 Gas Supply It is important that the gas supply pipe is sized correctly to provide the inlet pressure as stated on the heater data plate The gas supply pipe and electrical connections must not support any of the heater s weight 3 7 Electrical Supply A permanent 230 V 50 Hz 1 electrical supply is required at the main electrical terminals The heater also requires suitable energy controls in accordance with Section 9 COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL WARNING Fire Hazard Some objects will catch fire or explode when placed close to heater Keep all flammable objects liquids and vapours the required distance away from the heater Failure to follow these instructions can result in death injury or property damage Figure 1 Installation Clearances and Clearances to Combustibles Installation Clearances Clearances to Combustibles Roof Terminal Intake z Terminal Heaters may be mounted at a higher level if destratification 80 cm is necessary to service fans are installed heater The heater must always be installed at least 1 8 m above the floor The flue pipe must have clearance from combustibles by 5 cm If installed at low levels where individuals
27. minate when the control has gone to lockout This may be caused by flame failure Press the reset button on the back of the heater See Page 5 Section 4 1 or the remote reset if installed on site 11 4 Lighting Instructions 11 4 1 To Turn On Heater 1 Ensure that the electrical and gas supplies to the heater are on Check that the on site con trols are ON NOTE The thermostat setting must be above the ambient temperature for the heater to operate 2 The automatic firing sequence will begin as described on Page 16 Figure 9 The heater will now operate automatically under the control of the on site controls Following long shut down periods the control may go to lockout See Page 18 Section 11 3 3 11 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 4 The limit thermostat may have operated This may be caused by an interruption of the electri cal supply or failure of the distribution fan If the limit thermostat persistently operates there is a fault which must be investigated by a contractor qualified in the installation and service of
28. n rear of heater or remote reset button if fitted Is red lockout light on Is 230 V supply at fan connections Does flue fan run 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 15 5 Does air pressure switch change over Is HT lead okay and connected Is spark electrode okay Wait 30 40 seconds Is ignition spark operating Is the gas valve operating To test valve See Section 14 4 Does the flame light Is the flame current at least 1 u Amp DC when the flame lights Is red lockout light on If problems persist contact Roberts Gordon Ltd at Tel 44 0 1902 498733 www rg inc com Heater Operating TROUBLESHOOT ENDS Yes Yes WARNING Electrical Shock Hazard Do not touch ignition components Voltage from ignition components is high Failure to follow these instructions can result in death or electrical shock Flue fan faulty replace Ignition control faulty replace See Section 15 6 Replace valve Trace fault in supervision system See Section 14 3 For your safety and optimum heater performance use only ROBERTS GORDON replacement parts Conduct Commissioning procedure as shown on Page 15 Section
29. nion Appliances designed for other countries non European Union are available on request This appliance must be installed in accordance with the local and national codes in force and used only in a sufficiently ventilated space as specified in these instructions Before installation check that the local gas distribution systems nature of gas and pressure and adjustment of the appliance are compatible 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 Installation service and annual inspection of heater must be done by a registered installer contractor qualified in the installation and service of gas fired heating equipment Read this manual carefully before installation operation or service of this equipment This heater is designed for heating non residential indoor spaces Do not install in residential spaces These instructions the layout drawing local codes and ordinances and applicable standards that apply to gas piping electrical wiring venting etc must be thoroughly understood before proceeding with the installation SECTION 2 INSTALLER RESPONSIBILITY To install the heater as well as the gas and elec trical supplies in accordance wi
30. nnections Connect the heater to the gas supply ensuring that the final connections are as follows Gas supply pipe work is run in medium or heavy gauge tubing in compliance with local and national codes The gas supply pipe is adequately sized to carry the total volume of gas for the complete WARNING Fire Hazard installation Connect gas supply according to Figure 8 An isolating valve and union connection should nd fitted into th jacent to th Gas can leak if not installed properly be used and fitted into the supply adjacent to the heater Failure to follow these instructions can result in death e For suspended heaters use an approved metal injury or property damage flexible connection between the isolating valve and the heater To reduce pressure loss use It is important that the gas supply pipe and the one pipe size larger than the heater gas electrical connections do not support any of the connection heater s weight A gas meter is connected to the service pipe by the IMPORTANT The complete installation must be gas supply company An existing meter should be purged and tested for gas soundness in accordance checked preferably by the company to ensure that with local and national codes the meter is adequate for the rate of gas supply required Installation pipes must be fitted in accordance with local and national codes Pipe work from the meter to the heater s must be of adequate size Pipes of
31. nsion 8 Figure 4 Vertical Louvres Optional 8 Figure 5 Flue and Roof 9 Figure 6 Vertical and Horizontal Flue Termination B gt Appliance 10 Figure 7 Vertical and Horizontal Flue Termination Type amp Ce Appliances 10 Figure 8 Gas Connection with Stainless Steel Flex Connector ea 12 Figure 9 Automatic Burner Control Box Sequence 16 Figure 10 Gas Valve for Heater Models 7 32 16 Figure 11 Heater Operating 18 ee COMBAT Compact Tubular Unit Heaters are high efficiency heaters and are listed on as the Enhanced Capital Allowance Scheme Energy Technology Product List The ETL i symbol is a UK registered certification mark of The Carbon Trust Authorised User No 00184 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 U
32. paired 13 COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL 9 3 CTCUA Wiring Diagram Models 7 32 SITE WIRING WHLNAN IVLSOWYSAHL NO 110 38 m m E A o a 4j m n m 4 NOLLVOIGNI LNOADOT 3 LOW3H ee 2 gt 230 V 50 Hz SUPPLY NOTE m N H cL amp va MOTI3A N33H9 7 POLE PLUG AVLSOWYSHL LY ANNOHD YELLOW BLACK emo e nil BLUE r BROWN YELLOW PRESSURE SWITCH Ig BLACK BROWN PINK PURPLE GREY L HIKIHIKI DAN AANA An Ann AAA IOHLNOO NOLLINDI YOLVOIGNI HLIM L393H 104201 eio ef LE SOCKET zm COMBUSTION FAN AXIAL FAN FAN DELAY THERMOSTAT EMC FILTER E IWLSOWHSHL MEN Iu lin E NOLLINOI _ IOHLNOO NOLLINDI If any of the original wire supplied with the heater must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C and 600 volts 14 SECTION 10 COMMISSIONING Installation service commissioning and annual inspection of the heater must be done by a contractor qualified in the installation and servic
33. parts Failure to follow these instructions can result in property damage Roberts Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation this is entirely the responsibility of the installer It is essential that the contractor the sub contractor or the owner identifies the presence of combustible materials corrosive chemicals or halogenated hydrocarbons anywhere in the premises Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements fluorine chlorine bromine etc These compounds are frequently used in refrigerants cleaning agents solvents etc If these compounds enter the air supply of the burner the lifespan of the heater components will be greatly reduced Warranty will be invalid if the heater is exposed to halogenated hydrocarbons 2 3 National Standards and Applicable Codes All appliances must be installed in accordance with the latest revision of applicable standards and local and national codes This refers also to the electric gas and venting installation Note Additional standards for installations in public garages aircraft hangars etc may be applicable SECTION 3 CRITICAL CONSIDERATIONS SECTION 3 CRITICAL CONSIDERATIONS 3 1 Basic Information 3 8 Flue CTCU heaters have automatic ignition burners for Choose heater siting to allow for the proper location ON OFF operation only of th
34. r inlet d z Disconnect wire harnes Description Part Number Gas Valve VK4105A 90033403 Ignition Control 90434010 Replace in reverse order Verify that the gas flow direction of the valve is correct Use a minimum amount of gas seal on the thread joint Check that all the joints are leak free Reset gas valve See Page 17 Section 10 2 2 IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVE IS USED WHEN REPLACING THESE CONTROLS 26 15 2 Burner Compartment Pr Burners Injectors lt 3 Manifold Mounting Bracket _ 539 gt Gromet 7 gt Burner Compartment Cover Viewing Port Flame Probe Remove flexible SECTION 15 REMOVAL AND REPLACEMENT PARTS 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 Ignition Electrode air duct from spigot Remove screws and pull off burner cover Manifold Remove manifold screws and pull out manifold Unscrew Injectors Ensure gas tight fitting of injectors Ensure correct alignment with burners Ensure all pipe joints are gas tight MODEL CTCU 7 CT
35. service where necessary using only ROBERTS GORDON replacement parts Further Information Applications engineering and detailed guidance on systems design installation and product performance is available through ROBERTS GORDON representatives Please contact us for any further information you may require including the Installation Operation and Service Manual This product is not for residential use This document is intended to assist licensed professionals in the exercise of their professional judgement 2006 Roberts Gordon LLC All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage www rg inc com and retrieval systems without written permission of Roberts Gordon LLC Printed in U S A
36. shooting for Flame Supervision System 24 3 4 Clearances to Combustibles 3 14 4 Troubleshooting for Solenoid Valves 25 3 5 Ventilation oiii cn ce 3 14 5 Troubleshooting for Main 25 3 6 Gas Supply SECTION 15 Removal and Replacement Parts 26 3 7 Electrical Supply sen nn 3 15 1 Gas nerd een 26 gt 14 2 PRRERAEREERRERETERSEREESFERPERER TULTEUFEHETEFEFEHFRFUHEEEERERFFRLERRFPABER 3 15 2 Burner Compartment 27 SECTION 4 Specifications 5 15 3 Ignition Electrode and Flame Probe 28 4 1 CTCUA All Models eene 5 15 4 Flue Fan Vertical Installation 29 4 2 General Technical Data Table All Models 6 15 5 Pressure Switch sse 30 4 3 Technical Data Table All Models 6 15 6 Ignition Control 31 SECTION 5 Heater Installation 7 15 7 CTCUA Axial Fan Guard Motor Assembly 31 General y A uu ua hinasqa 7 15 8 Fan and Limit Thermostats 31 5 2 Shelf Mounting and
37. smaller size than the heater inlet gas connection should not be used Figure 8 Gas Connection with Stainless Steel Flex Connector Hold gas nipple securely with pipe wrench when attaching the flex gas connector Do not twist flexible uh 4 ELI UN gas connector Flex Gas Connector Ensure all joints are gas tight Do not bend flexible gas connector sharply Option B Medium or Heavy Gas Isolating Valve Gauge Tubing O Gas Connector Drip Leg Hara p Union i Connection SECTION 9 WIRING AND ELECTRICAL INFORMATION SECTION 9 WIRING AND ELECTRICAL INFORMATION 9 1 Electrical Supply All heater models need a constant 230 V 50 Hz 1 Y supply connected to terminals L N amp Earth Polarity L 8 must be correct The voltage between neutral and earth should be O and never exceed 15 volts All heaters and controls must be correctly earthed All external wiring must comply with the relevant local codes Wire specification H05VV F External controls must have the same constant 230 V 50 Hz supply An isolator with a contact separation of at least 3 mm on all poles must be installed adjacent to but not attached to the heater to disconnect all supplies to the heater and any remote control This switch should be fused to 5 A
38. switch change over Required Incoming Signals Signals Output By Control ENDESA If at any stage the flame fails the control will go into lockout The red light inside the RESET switch will illuminate and the control will need to be manually reset before any further start attempt can be made Figure 10 Gas Valve for Heater Models 7 32 End View Ignition Control Plugs into Gas Valve 12 Cable Connector Outlet Pressure Inlet Pressure Gas Inlet 16 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 Tech nical Data Tables for the correct gas and model on Page 6 Section 4 3 NOTE If the correct burner pressure cannot be reached then check the inlet pressure to the valve with the burner firing See Technical Data Tables on Page 6 Section 4 3 for inlet pressure requirement Do not continue to adjust the regulator if the pressure is not changing 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 adjus
39. t 11111511K Hanging M10 Description Part Number Wall Suspension Mounting Bracket Kit 11111511K Wall Mounting Bracket Arm Left 111WALL1L Wall Mounting Bracket Arm Right 111WALL1R Wall Mounting Bracket Vertical 111WAL2 Wall Mounting Bracket Diagonal 111WAL3 M8 x 85 mm Hex Head Bolt 97311405 M8 Lock Nut with Nylon Insert 92204504 M8 Flat Washer 95204502 M8 Lockwasher 900 oF ro SEN 9 96404502 Hardware provided to construct mounting bracket assembly only Figure 4 Vertical Louvres Optional Remove Horizontal Louvres Install Vertical Louvre Brackets top and bottom with supplied screws Install Vertical Louvres and Springs into Brackets with Springs at Top Push in Louvre and_compress spring to remove Description Part Number Description Part Number Description Part Number Vertical Louvre Kit CTCU 7 and 11 11111901K Vertical Louvre Bracket 11111903 Vertical Louvre Kit CTCU 15 and 22 Vertical Louvre Bracket 11111900K 11111903 Vertical Louvre Kit CTCU 27 and 32 11111902K Vertical Louvre Bracket 11111903 10 Screw S103 10 Screw S103 10 Screw S103 CTCU 7 11 Vertical Louvres 11111901 Louver Spring 90901200 Instruction Sheet 91040021 Ins
40. th applicable specifications and codes Roberts Gordon recommends the installer contact a local building inspector Fire Officer or insurance company for guidance To use the information given in the manual together with the local and national codes to perform the installation To install the heater in accordance with the clearances to combustibles of this heater To furnish all needed materials not furnished as standard equipment To plan location of supports flues and air intakes To provide access to burners for servicing To provide the owner with a copy of this Installation Commissioning Operation and Service Manual To never use heater as support for ladder or other access equipment and never hang or suspend anything from heater To ensure that there is sufficient ventilation in the area to comply with the requirements of all relevant local and national codes 2 1 Clearances to Combustibles In all situations clearances to combustibles must be maintained Caution must be used when running the heater near combustible materials such as wood paper rubber etc A wall tag is on the back cover of this manual as a permanent reminder of the safety instructions and the importance of the required 2 clearances to combustibles Affix the tag on a wall near the heater 2 2 Corrosive Chemicals CAUTION Do not use heater in an area containing corrosive chemicals Corrosive chemicals will damage the burner and heat exchanger
41. tment allow the heater to operate for at least 15 minutes and then re check settings 2 Remove the manometer and refit all covers to the valve and tighten the screw of the outlet pressure tap 3 Check gas flow rate at gas meter 10 2 3 Combustion Testing The only adjustment to alter combustion performance is burner pressure Combustion quality must be tested to prove correct heater operation Incorrect results will indicate faults with the installation or appliance Combustion testing must be carried out with all covers in place The flue gas is sampled in the flue within 1 meter of the heater The values of CO should be between 5 7 to 8 0 for natural gas and 6 8 to 9 2 for LPG dependant upon model The CO will be up to 80 ppm 0 008 dry air free dependant upon model Temperature rise of the flue gases above ambient should be approximately 130 C to 160 C Seal test hole in flue after testing 10 2 4 Pressure Switch The pressure switch is factory pre set for each model and is not adjustable SECTION 10 COMMISSIONING 10 2 5 Turning Off the Heater Set the external controls to the OFF position and the main burner will stop The fan will run until it is stopped automatically by the fan thermostat Do not use Electrical Isolator for control of heater Electrical Isolator will switch off the fan Heat exchanger could be damaged Warranty will not cover damage to the heat exchanger if operated improperly 10 2 6
42. truction Sheet For models 15 and 22 horizontal louvres are re used 91040021 27 32 Vertical Louvre 11111902 Instruction Sheet 91040021 SECTION 6 FLUE INSTALLATION SECTION 6 FLUE INSTALLATION 6 1 Changing Flue and Air Intake Orientation Figure 5 Flue and Roof Detail The heater is sold with horizontal flue and fresh air connections as standard If vertical flue and fresh air connections are required follow the instructions on Page 29 Section 15 4 Flue Terminal 6 2 Flue Installation WARNING Masterflash Soaker Flashing or Rain Oollar 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 8 injury or property damage 25 mm Air Gap to Flue Combustible Material The flue must terminate outside of the building Flues and air intakes must be a fully sealed system and correctly sized for the model Flues should be assembled as detailed on Page 9 Figure 5 through Page 10 Figure 7 The joints between the flue terminal and the roof or wall must be properly sealed If the flue passes through a wall or ceiling of combustible material it must be enclosed by a sleeve of non combustible material and be separated from the sleeve by at least a 25 mm air gap Flues and air
43. ttached to a suitable wall through all mounting holes Screw sizes less than M10 may not be used In order for the wall mounting brackets to adequately carry the weight of the heater it must be installed with best building practice Ensure all suspension hardware is torqued to a minimum Channel Nut s Nr ft lbs x Drop Rod Nut Washer Za Riv Nut Shelf Mounting Brackets Cone Point 7 Clamp Part Number 11111510K 111111510 94311008 Description Shelf Mounting Bracket Kit Shelf Mounting Bracket 2 Screw 10 x 1 2 Type AB Phil HWH Z 2 Support Points NOTE For vertical installations use the mounting points on the rear of the unit Existing cabinet screws must be re used COMBAT CTCU Unit HEATER INSTALLATION OPERATION AND SERVICE MANUAL Figure 3 Shelf Mounting and Hanging Suspension Shelf Mounting Shelf Mounting Brackets Fasten to Bracket Pm Wall Mounting Bracket Arm Right amp Left M8 Bolt Washer Lock Washer M8 Locknut Torque to 4 5 Nm 40 in Ib 4 Wall Mounting X Wall Mounting Bracket Diagonal Wall Mounting Bracket Vertical Description Part Number Wall Shelf Mounting Bracket Kit 11111512K Wall Suspension Mounting Bracket Kit 1111510K Shelf Mounting Bracket Ki
44. ue fan should not require maintenance However if the air pressure switch is causing burner lockout then remove the flue fan from the vent box by unscrewing the three screws at the mounting plate Remove the four screws attaching the mounting plate to the fan inlet See Page 29 Section 15 4 Ensure that the fan is free to run and that the fan wheel is clean SECTION 13 CONVERSION BETWEEN GASES 13 1 General Conversion between gases will require a change of burner injectors and the gas valve re commissioning to the new conditions 13 2 Burner Conversion Conversion of the burner assembly from one gas to the other is the same for all types of heaters 1 Remove the burner compartment cover as shown on Page 27 Section 15 2 2 Remove the 4 screws holding the manifold and pull out the manifold 3 Remove inshot burners by rotating them and sliding out the bracket 4 Remove the main burner injectors 5 Replace with the injectors for the new gas ensuring a gas tight seal 6 Refit all components in reverse order 13 3 Gas Valves All gas valves used on the CTCU have pressure regulators that may be set to operate on natural gas or LPG Conversion is carried out by re setting the burner pressure to the value in the data table during commissioning See Page 6 Section 4 3 Ensure that the gas inlet pressure to the heater is correct for the new gas and that the gas supply has been purged of the old gas SECTION 13 CONVERSIO
45. un u rt Open windows DO NOT try to light any appliance DO NOT use electrical switches DO NOT use any telephone in your building Leave the building 6 Immediately call your local gas supplier after leaving the building Compact Tubular Unit Heaters Follow the gas supplier s instructions If you cannot reach your gas Installation Commissioning supplier call the Fire Department A WARNING Operation Service Manual Models CTCU 7 CTCU 11 CTCU 15 CTCU 22 CTCU 27 Fire Hazard Do not store or use petrol or other CTCU 32 flammable vapours and liquids in the vicinity of this or any other appliance f 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 Installer 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 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 Installation must be done by a registered installer contractor qualified in the installation and service of gas fired heating equipment or your
46. y If the heater is used in a dirty or dusty area more frequent maintenance may be necessary Installation Code and Annual Inspections All installations and service of ROBERTS GORDON products must be performed by a contractor qualified in the installation and service of gas fired heating equipment and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service and operation of the equipment To help facilitate optimum performance and safety Roberts Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON products and perform service where necessary using only ROBERTS GORDON replacement parts A WARNING Cut Hazard Turn off gas and electrical supply before maintenance Fan can start automatically at any time Failure to follow these instructions can result in severe injury or product damage NOTE 1 After any maintenance or repair work always test fire the heater in accordance with the commissioning instructions on Page 15 Section 10 through Page 17 Section 10 3 1 to ensure all safety systems are in working order before leaving the heater to operate Minor faults may be traced by using the troubleshooting charts on Page 22 Section 14 through Page 25 Section 14 5 NOTE 2 Check all gas pipes and pipe joints to ensure there are no cracks or gas leaks Any cracks in the pipes or pipe joints must be repaire
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