Page 3 - TABLE OF CONTENTS
© 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 wri...
Page 5 - TABLE OF FIGURES; Figure 1: Installation Clearances and Clearances to
TABLE OF FIGURES Figure 1: Installation Clearances and Clearances to Combustibles.............................................................. 4 Figure 2: Suspension Methods ................................................. 7Figure 3: Shelf Mounting and Hanging Suspension .................. 8Figure...
Page 7 - COMBAT; Product Approval
1 COMBAT ® Compact Tubular Unit Heaters are high efficiency heaters and are listed on the Enhanced Capital Allowance Scheme ’Energy Technology Product List’. The ETL symbol is a UK registered certification mark of The Carbon Trust. Product Approval ROBERTS GORDON ® appliances have been tested and CE...
Page 8 - SECTION 1: HEATER SAFETY; * Halogenated Hydrocarbons; National Standards and Applicable Codes; CAUTION; Do not use heater in an area containing corrosive
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 2 SECTION 1: HEATER SAFETY Your Safety is Important to Us!This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnin...
Page 9 - See Page 5, Section 4
SECTION 3: C RITICAL C ONSIDERATIONS 3 SECTION 3: CRITICAL CONSIDERATIONS 3.1 Basic Information CTCU heaters have automatic ignition burners for ON/OFF operation only. 3.2 Location and Suspension All models: • Must be installed indoors. • Must be installed in a level position with horizon- tal or ve...
Page 10 - WARNING; Clearances to Combustibles; * Heaters may be mounted at a higher level if destratification
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 4 Figure 1: Installation Clearances and Clearances to Combustibles WARNING Fire H a z ard S ome objects will catch fire or explode when placed close to heater. K eep all flammable objects, liquids and vapours the required dist...
Page 11 - SECTION 4: SPECIFICATIONS; Model; End View
SECTION 4: S PECIFICATIONS 5 SECTION 4: SPECIFICATIONS 4.1 CTCUA (All Models) Dimension Data - CTCUA (All Models) Model CTCU-7 CTCU-11 CTCU-15 CTCU-22 CTCU-27 / 32 A Height mm (in) 304 (12.0) 304 (12.0) 450 (17.7) 450 (17.7) 578 (22.8) B Mounting Hole Spacing mm (in) 239 (9.4) 239 (9.4) 385 (15.2) 3...
Page 12 - Reduce the maximum length stated by 1 m for each 90° bend installed.
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 6 4.2 General Technical Data Table (All Models) 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. ...
Page 13 - SECTION 5: HEATER INSTALLATION; For typical suspension,; Figure 2: Suspension Methods
SECTION 5: H EATER I NSTALLATION 7 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...
Page 14 - Figure 3: Shelf Mounting and Hanging Suspension; Hardware provided to construct mounting bracket assembly only.; Push in
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 8 Figure 3: Shelf Mounting and Hanging Suspension Hardware provided to construct mounting bracket assembly only. Figure 4: Vertical Louvres (Optional) For models 15 and 22, horizontal louvres are re-used. Shelf Mounting Bracke...
Page 15 - on
SECTION 6: F LUE I NSTALLATION 9 SECTION 6: FLUE INSTALLATION 6.1 Changing Flue and Air Intake Orientation The heater is sold with horizontal flue and fresh air connections as standard. If vertical flue and fresh air connections are required, follow the instructions on Page 29, Section 15.4 . 6.2 Fl...
Page 16 - Figure 6: Vertical and Horizontal Flue Termination - Type B
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 10 Figure 6: Vertical and Horizontal Flue Termination - Type B 22 Appliance Figure 7: Vertical and Horizontal Flue Termination - Type C 12 C 32 & C 62 Appliances Wall Terminal Flue Masterflash Masterflash Roof Terminal Ver...
Page 17 - SECTION 7: AIR SUPPLY; per kilowatt of total rated heat input and; Building Ventilation; and local and national
SECTION 7: A IR S UPPLY 11 SECTION 7: AIR SUPPLY 7.1 Room Sealed Installation When installed as a room sealed heater, the air for combustion is drawn in from outside the building. It is important to ensure that there is adequate ventilation to provide air for the distribution fan. 7.2 Open Flued Ins...
Page 18 - SECTION 8: GAS PIPING; Fire Hazard; Option
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 12 SECTION 8: GAS PIPING It is important that the gas supply pipe and the electrical connections do not support any of the heater’s weight.A gas meter is connected to the service pipe by the gas supply company. An existing met...
Page 19 - SECTION 9: WIRING AND ELECTRICAL INFORMATION; k H
SECTION 9: W IRING AND E LECTRICAL I NFORMATION 13 SECTION 9: WIRING AND ELECTRICAL INFORMATION 9.1 Electrical Supply All heater models need a constant 230 V 50 Hz 1 Ø supply connected to terminals L 1 , N & Earth. Polarity "L & N" must be correct. The voltage between neutral and ear...
Page 20 - SITE WIRING
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 14 9.3 CTCUA Wiring Diagram Models 7 - 32 GROUND AT LIMI T BLUE WHITE YELLOW BROWN BLACKBROWN 11 12 7 9 10 8 5 64 AXIAL FAN COMBUSTION FAN WHITE YELLOW PURPLE PINK GREY 2 3 1 L E N E N L PRESSURE SWITCH RED BLACK BLUE BRO W N ...
Page 21 - SECTION 10: COMMISSIONING
SECTION 10: C OMMISSIONING 15 SECTION 10: COMMISSIONING Installation, service, commissioning and annual inspection of the heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment. Read this manual carefully before installation, commissioning, opera...
Page 22 - Figure 9: Automatic Burner Control Box Sequence; START; *Purge time begins at pressure switch change over.
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 16 Figure 9: Automatic Burner Control Box Sequence Figure 10: Gas Valve for Heater Models 7 - 32 Burner sequence for Honeywell S4565C Flame Signal Start Gas Valve Ignition Spark Supply 230 V CLOSE DOWN RUN START ts = 10 second...
Page 23 - Check Gas Rate
SECTION 10: C OMMISSIONING 17 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 pressur...
Page 24 - See
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 18 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 ........
Page 25 - Simple Fault Finding; The time and/or temperature controls are not
SECTION 11: U SER I NSTRUCTIONS 19 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 Som...
Page 26 - Installation Code and Annual Inspections:; All
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 20 SECTION 12: SERVICING 12.1 Servicing Instructions After commissioning, the heater will require maintenance to be carried out annually. If the heater is used in a dirty or dusty area, more frequent maintenance may be necessa...
Page 27 - SECTION 13: CONVERSION BETWEEN GASES
SECTION 13: C ONVERSION B ETWEEN G ASES 21 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...
Page 28 - SECTION 14: TROUBLESHOOTING; Start; Conduct Commissioning procedure as shown
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 22 SECTION 14: TROUBLESHOOTING 14.1 General 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 Replace limit thermostat. The lim...
Page 29 - Troubleshooting For Automatic Ignition Burner Systems; WARN
SECTION 14: T ROUBLESHOOTING 23 14.2 Troubleshooting For Automatic Ignition Burner Systems If problems persist, contact Roberts-Gordon Ltd. at Tel: +44 (0) 1902 498733 www.rg-inc.com Heater Operating TROUBLESHOOT ENDS. No Trace fault in supervision system. See Section 14.3. Yes Is red lockout light ...
Page 30 - Troubleshooting for Flame Supervision System
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 24 14.3 Troubleshooting for Flame Supervision System Repair or replace as necessary. If problems persist, contact Roberts-Gordon Ltd. at www.rg-inc.com Control box faulty. Replace with correct type. Use Section 14.1 to trace t...
Page 31 - Troubleshooting for Solenoid Valves
SECTION 14: T ROUBLESHOOTING 25 14.4 Troubleshooting for Solenoid Valves 14.5 Troubleshooting for Main Fan Valve faulty. Replace with one of correct type. Fault elsewhere. If problems persist, contact Roberts-Gordon Ltd. at Tel: +44 (0) 1902 498733 www.rg-inc.com Valve Operating TROUBLESHOOT ENDS. N...
Page 32 - SECTION 15: REMOVAL AND REPLACEMENT PARTS; See warnings and notes; Burner Components; Remove the gas supply pipe at the heater inlet.
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 26 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. ...
Page 33 - Burner Compartment; MODEL
SECTION 15: R EMOVAL AND R EPLACEMENT P ARTS 27 15.2 Burner Compartment 15.2.1 Burner Injectors Remove flexible air duct from spigot. Viewing Port Flame Probe Burner Compartment Cover Ignition Electrode Remove screws and pull off burner cover. The burner compartment is a sealed compartment. Followin...
Page 34 - Ignition Electrode and Flame Probe; Burner Compartment
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 28 15.3 Ignition Electrode and Flame Probe Burners .120 (3 mm) spark gap Ignition Electrode Burner Compartment Front Views Limit Thermostat Ignition Electrode Flame Probe Fan Thermostat Flame Probe Burners Description Part Num...
Page 35 - Flue Fan Vertical Installation; Carry out a commission after working on or changing a flue fan.; Refit in reverse order.
SECTION 15: R EMOVAL AND R EPLACEMENT P ARTS 29 15.4 Flue Fan Vertical Installation 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 . MODEL CTCU-7 ...
Page 36 - See Page 15, Section; Pressure Switch
COMBAT ® CTCU U NIT H EATER I NSTALLATION O PERATION AND S ERVICE M ANUAL 30 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. Carry ou...
Page 37 - Ignition Control; Remove the screws
SECTION 15: R EMOVAL AND R EPLACEMENT P ARTS 31 15.6 Ignition Control The control plugs onto the gas valve. Pull out 12 pin electrical connection. Pull out ignition cable and flame probe cable noting their positionsRelease screw securing control to gas valve.Refit in reverse. Ensure correct location...