Roberts-Gordon CTU 22 TO 115 - Manuals

Page 3 - TABLE OF CONTENTS; Distribution Duct Work for CTUB, CTUC and CTUD

© 2007 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 ................................................. 9Figure 3: Flue and Roof Detail ..............................................

Page 8 - SECTION 1: HEATER SAFETY; CAUTION; Do not use heater in an area containing corrosive; * Halogenated Hydrocarbons; National Standards and Applicable Codes

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 2 SECTION 1: HEATER SAFETY Your Safety is Impor tant 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 warni...

Page 9 - See Page 5, Section 4

SECTION 3: C RITICAL C ONSIDERATIONS 3 SECTION 3: CRITICAL CONSIDERATIONS 3.1 Basic Information CTU 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. • May be mounted on a s...

Page 10 - WARNING; COMBAT; 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 distance away from the heater. Failure to follow these instructions can result in death, injury or property damage. COMBAT ® CTU U NIT H EATERS I...

Page 11 - SECTION 4: SPECIFICATIONS; Rear View

SECTION 4: S PECIFICATIONS 5 SECTION 4: SPECIFICATIONS 4.1 CTUA A B Rear View End View Z 646 168 Gas Supply F G H Top View J E C D 77 Heater must be supported at these points from above or below. 492 Support Centers 4 x M10 Captive Nuts Provided Lockout Reset Electrical Cable Entry Air Intake Flue M...

Page 12 - End View; Inlet and outlet duct spigot fitted with 30 mm flange.

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 6 4.2 CTUB, CTUC and CTUD 115 115 End View CTUB/C (All Models) 115 End View CTUC (All Models) End View CTUD (All Models) Front View CTUD (And other models fitted with air outlet spigots) N N 646 P N M L N K 1440 679 646 Model ...

Page 13 - General Technical Data Table; maximum length stated by 1 m for each 90° bend installed.

SECTION 4: S PECIFICATIONS 7 4.3 General Technical Data Table Model CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115 CTUA With Axial Fan Total Electrical Load W 210 210 210 210 415 415 510 510 745 745 Run Current A 1.0 1.0 1.0 1.0 1.72 1.72 1.9 1.9 3.2 3.2 Start Current A 1.4 ...

Page 14 - Technical Data Table; Appliance Category II; Gas rates corrected to standard conditions 1013.25 mbar 15° C.

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 8 4.4 Technical Data Table Appliance Category II 2H/L 3B/P Model CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-100 CTU-115 Heat Input Gross CV kW (Btu/h) x (1000) 2793 33 113 39 133 48 163 61 210 70 238 95 324 11...

Page 15 - SECTION 5: HEATER INSTALLATION; For typical suspension; Figure 2: Suspension Methods

SECTION 5: H EATER I NSTALLATION 9 SECTION 5: HEATER INSTALLATION 5.1 General Heaters are designed for installation above 2.5 m. These heaters must be installed within the heated space. Duct delivery systems are not permitted with axial fans. 5.2 Handling All CTU heaters are supplied secured to a wo...

Page 16 - . The joints between the flue

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 10 SECTION 6: FLUE INSTALLATION 6.1 Flue Installation 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 distance away fro...

Page 17 - Figure 5: Vertical and Horizontal Flue Termination - Type B; Appliances

SECTION 6: F LUE I NSTALLATION 11 Figure 5: Vertical and Horizontal Flue Termination - Type B 22 Appliance Wall Terminal Air Intake Terminal Cover Flue Masterflash Masterflash Roof Terminal Vertical Option Horizontal Option 90° Bend Flue Metal Sleeve (25 mm air gap to Combustible Material) Figure 6:...

Page 18 - See Page

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 12 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 provid...

Page 19 - SECTION 8: OPTIONAL HEATER CONFIGURATIONS; on Page

SECTION 8: O PTIONAL H EATER C ONFIGURATIONS 13 SECTION 8: OPTIONAL HEATER CONFIGURATIONS 8.1 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 ...

Page 20 - SECTION 9: GAS PIPING; To reduce pressure loss, use; Option

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 14 SECTION 9: GAS PIPING WARNING Fire Hazard Connect gas supply according to Figure 9 . Gas can lea k if not installed properly. Failure to follow these instructions can result in death, injury or property damage. It is import...

Page 21 - SECTION 10: WIRING AND ELECTRICAL INFORMATION; All heaters and controls must be correctly earthed.; Models; ROBERTS GORDON; A room thermostat or ROBERTS GORDON

SECTION 10: W IRING AND E LECTRICAL I NFORMATION 15 SECTION 10: WIRING AND ELECTRICAL INFORMATION 10.1 Electrical Supply All heaters need a constant 230 V 50 Hz single phase supply connected to terminals L, N & Earth. Polarity "L & N" must be correct. The voltage between neutral and ...

Page 22 - IGNITION MODULE

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 16 10.3 CTUA Wiring Diagram (Models 22-60) IGNITION MODULE BLACK Plug in Connection to Gas Valve S4565C 1017 Control Honeywell BLACK SENSE IGNITION 230 V 1 Ø 50 Hz IGNITION MODULE LOCKOUT GAS VALVE RUN 11 12 7 9 10 8 5 6 4 SIT...

Page 23 - SITE WIRING

SECTION 10: W IRING AND E LECTRICAL I NFORMATION 17 10.4 CTUA Wiring Diagram (Models 75-115) S 4563 C Honeywell 230 V 1 Ø 50 Hz SITE WIRING N L 1 2 3 7 8 REMOTE LOCKOUT RESET REMOTE LOCKOUT INDICA TION THERMOST AT REMOTE F AN ON LINE NEUTRAL GROUND L N E COMBUSTION F AN AXIAL F AN L N E BROWN RED NC...

Page 27 - For external fan wiring,

SECTION 10: W IRING AND E LECTRICAL I NFORMATION 21 10.8 CTUD Wiring Diagram (Models 22-60) IGNITION MODULE BLACK Plug in Connection to Gas Valve S4565C 1017 Control Honeywell BLACK SENSE IGNITION 230 V 1 Ø 50 Hz IGNITION MODULE LOCKOUT GAS VALVE RUN 11 12 7 9 10 8 5 6 4 SITE WIRING 2 3 1 N L 1 2 3 ...

Page 28 - SITE

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 22 10.9 CTUD Wiring Diagram (Models 75-115) S 4563 C Honeywell L N E COMBUSTION F AN NC\P(2) Pressure Switch Detail NO\P(3) C \P(1) BLACK YELLOW WHITE PRESSURE SWITCH BLUE PINK GREY PURPLE LOCKOUT RUN GREEN/YELLOW BLACK WHITE ...

Page 29 - CTUD External Motor Alternative Wiring; Frost

SECTION 10: W IRING AND E LECTRICAL I NFORMATION 23 10.10 CTUD External Motor Alternative Wiring 2A 230v L L L 1 2 3 N 400 V 3 Ø motor Three Phase Motor 400 V 50 Hz 3 Ø Supply N L 1 2 3 Contactor or Relay Overload protection must be provided at the motor or contactor. Room Thermostat Frost Thermosta...

Page 30 - SECTION 11: COMMISSIONING; through Page; Mechanical Checks

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 24 SECTION 11: 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 care...

Page 31 - Figure 10: Automatic Burner Control Box Sequence; CLOSE; *Purge time begins at pressure switch change over.

SECTION 11: C OMMISSIONING 25 Figure 10: Automatic Burner Control Box Sequence Burner sequence for Honeywell S4563 or S4565C Flame Signal Start Gas Valve Ignition Spark Supply 230 V CLOSE DOWN RUN START ts** Signals Output By Control Flue Fan Pressure Switch P C NO NC 30 Sec. Purge* *Purge time begi...

Page 32 - on; Check Gas Rate

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 26 Figure 12: Gas Valve for Heater (Models 75 - 115) Regulator (Under Cover) Inlet Pressure Gas Outlet Outlet Pressure Plug for Main Gas Valve Gas Inlet Plug for Main Safety Gas Valve 11.4.2 Commissioning the Gas Valves (all g...

Page 33 - External Controls; Give this manual to the user.

SECTION 11: C OMMISSIONING 27 11.7 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. 11.8 Complete the Commiss...

Page 34 - Press to reset

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 28 SECTION 12: USER INSTRUCTIONS 12.1 User Instructions 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 - Simple Fault Finding

SECTION 12: U SER I NSTRUCTIONS 29 12.4.2 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”. 12.5 Simple Fault Finding Some possible rea...

Page 36 - See Page 36, Section

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 30 SECTION 13: SERVICING 13.1 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 37 - SECTION 14: CONVERSION BETWEEN GASES; See Page 35, Section

SECTION 14: C ONVERSION B ETWEEN G ASES 31 SECTION 14: CONVERSION BETWEEN GASES 14.1 General Conversion bet ween gasses will require a change of burner injectors and the gas valve re-commissioning to the new conditions. 14.2 Burner Conversion Conversion of the burner assembly from one gas to the oth...

Page 38 - SECTION 15: TROUBLESHOOTING; Start; Conduct Commissioning procedure as shown; Installation Code and Annual Inspections:; All; equipment must be performed by a; manuals and all; ROBERTS; equipment and perform service

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 32 SECTION 15: TROUBLESHOOTING 15.1 General If problems persist, contact ROBERTS GORDON ® at Tel: +44(0)121 506 7709 www.rg-inc.com Heater Operating TROUBLESHOOT ENDS. No Check for mis-wiring. Change time delay relay. Check ti...

Page 39 - Troubleshooting For Automatic Ignition Burner Systems; WARN

SECTION 15: T ROUBLESHOOTING 33 15.2 Troubleshooting For Automatic Ignition Burner Systems Heater Operating TROUBLESHOOT ENDS. No Trace fault in supervision system. See Section 16.3. No Yes Is red lockout light on? No Is the flame current at least 1 µAmp DC when the flame lights? Ignition control fa...

Page 40 - Troubleshooting for Flame Supervision System; START; Troubleshooting for Solenoid Valves; ST

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 34 15.3 Troubleshooting for Flame Supervision System Repair or replace as necessary. Control box faulty. Replace with correct type. Use section 15.1 to trace the fault. Heater Operating TROUBLESHOOT ENDS. No Repair or replace ...

Page 41 - SECTION 16: REMOVAL AND REPLACEMENT PARTS; See warnings and notes; Burner Components; Section 4; See

SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 35 SECTION 16: REMOVAL AND REPLACEMENT PARTS See warnings and notes on Page 30, Section 13 before removing or replacing parts. Burner Components All serviceable burner parts are accessed by the door on the right side of the heater. Use a screwdriver to tu...

Page 42 - Burner Compartment; Ensure gas tight fitting of injectors.; Burner Injectors

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 36 16.2 Burner Compartment Remove flexible air duct from spigot Remove access plate Remove screws and pull off burner cover Viewing port for flame probe Viewing port for ignition electrode Flame probe Burner compartment cover ...

Page 43 - Ignition Electrode and Flame Probe; front view of the burner compartment.

SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 37 16.3 Ignition Electrode and Flame Probe Description Part Number Spark Electrode 90427411 Automatic Ignition Flame Probe 90439300 Burners (all models except CTU-40) 92000000 Burners - CTU-40 92000001 Flame Probe Ignition Electrode Remove Screw Ignition ...

Page 44 - Carry out a commission after working on or changing a flue fan.

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 38 16.4 Flue Fan Vent Box Outlet Gasket Flue Fan Vent Box Screws Flue Adapter Flue Adapter to Flue Fan screws Rear Panel Hole Disconnect electrical connections at plug in tabs. Mounting Plate to Vent Box Screws Mounting Plate ...

Page 45 - See Page 24, Section; Pressure

SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 39 16.5 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. C ar b on M ono x ide H a z ard U se ...

Page 46 - Ignition Control; Remove the four screws; and Replacement

COMBAT ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M ANUAL 40 16.6 Ignition Control IT IS IMPORTANT THAT ONLY THE CORRECT IGNITION CONTROL SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS. 16.6.1 S4565C Models 22 to 60 This control plugs onto the gas valve. Pull out 12...

Page 47 - • Use only genuine ROBERTS GORDON; Figure 14: Centrifugal Fan Orientation

SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 41 • Use only genuine ROBERTS GORDON ® replacement parts. 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 wind...

Page 51 - Attach this information to the wall near the ROBERTS GORDON

WARNING © 2007 Roberts-Gordon, LLC www.rg-inc.com Printed in U.S.A. P/N 91040028 Rev B Attach this information to the wall near the ROBERTS GORDON ® heater Read the Installation, Commissioning, Operation and Service Manual thoroughly before installation, operation or service. OPERATING INSTRUCTIONS ...