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Roberts Gorden CTCU 32 manual

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Table of contents for the manual

  • Page 1

    W ARNING FOR Y OUR SAFETY If you smell g as: 1 . Open windo ws. 2. DO NO T try to light an y appliance. 3. DO NO T use electrical s witches. 4. DO NO T use any t elephone in your b uilding. 5. Extinguish any open f lame . 6. Leav e the build ing. 7 . Immediatel y call your local gas supplier af ter leaving the b uilding. F ollow the gas supplier ?[...]

  • Page 2

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  • Page 3

    © 20 1 1 Ro b er ts-Gordon Eur ope Ltd All rights reserved. N o par t of this wor k cov ered b y the copyrights herein ma y b e repr oduced or copied in any f or m or b y any means - g raphic, electr onic, or mechanical, including photocop ying, r ecording, taping or inf or mation stor age and retrie val s ystems - w ithout the writt en per missio[...]

  • Page 4

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  • Page 5

    TABLE OF FIGURES Fig u re 1: F ront and Back P anel Label Placement .................... . 2 Fig u re 2: Side P anel Label Placement ............... .............. ......... 3 Fig u re 3: Installation Clearances and Clearances to Com b u stib les ..................... .............. .............. ............ 6 Fig u re 4 : S u spension Methods ..[...]

  • Page 6

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  • Page 7

    1 of 42 COMB A T ® C ompact T u b u lar Unit Heat ers ar e high ef f iciency heat ers and ar e listed on the Enhanced C apital Allo w a nce Scheme ’Energy T echnology P r od u ct List’ . The ETL symbol is a UK regist ered cer tif ication mark of The Carbon T r u st. Pr o d u ct Appr o v al ROBERTS GORDON ® appliances have been tested and CE c[...]

  • Page 8

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 2 of 42 SECTION 1: HEATER SAFETY Yo u r Saf et y is Impor tant t o Us! This s ymbol is u sed thr o u gho u t the man u al t o notify yo u of possib le f ir e, electrical or b u r n hazards . Please pay special at tention w hen r eading and fo l l o w ing the w arnings in [...]

  • Page 9

    SECTION 1: H EAT ER S AFETY 3 of 42 Fi g ur e 2: Side P anel L abel Placement Description Part Number Lighting Label 91 040002 Wir ing Diagram Label 91 040020[...]

  • Page 10

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 4 of 42 SECTION 2: INSTALLER RESPONSIBILITY • T o install the heat er , as w ell as the g as and elec- trical s u pplies , in accor dance w ith applicab le specif ications and codes . Roberts-Gordon recommends the inst aller contact a local b u ildin g inspect or , Fir [...]

  • Page 11

    SECTION 3: C LEARANCES TO C OMBUSTIBLES 5 of 42 SECTION 3: CLEARANCES T O COMBUSTIBLES 3.1 R e q uired Clearan ces to Comb ustibles Clearances ar e the req u ir ed distances that comb u stib le objects m u st be a w a y from the hea ter to p re v ent f ire hazar ds. C a u tion sho u ld be u sed w hen r u nning the sy stem near comb u stibles . Com [...]

  • Page 12

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 6 of 42 Fi g ur e 3: Installation Clear ances and Clear ances to Comb ustibles If installed at lo w le v els w here indi v id u als can come in cont act w ith h ot heat e x changer components, adeq u at e g u ard ing m u st be pr o v ided. All distances ar e minim u m cle[...]

  • Page 13

    SECTION 4: C RIT CA L C ONSIDERATIONS 7 of 42 SECTION 4: CRITCAL CONSI DERATIONS 4.1 V entilation It is impor tant to ens u re that t here is adeq u ate air circ u lation aro u nd the heate r to s u pply air f or comb u stion, v entilation and distrib u tion in accor dance w ith local and national codes . 4.2 Gas Suppl y It is impor tant that the g[...]

  • Page 14

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 8 of 42 SECTION 5: SPECIFICATIONS 5.1 CTCU A (All Models) Dimension Data - CTCU A (All Models) Model CTCU-7 CTCU-1 1 CTCU -1 5 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 H ole Spacing mm (in) 239 (9.4) 239 (9.4)[...]

  • Page 15

    SECTION 5: S PECIF ICATIONS 9 of 42 5.2 Gener al T echnica l Data T able (All Models) Electr ical load at 230 V 50 Hz meas u red by c al c u lating from to tal r u n c u rrent of ap pliance. * Do not e x ceed the maxim u m length of f l u e stat ed or heater ma y not operat e properly . Re d u ce the maxim u m length stat ed by 1 m f or each 90° b[...]

  • Page 16

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 1 0 of 42 SECTION 6: HEATER INSTALLATION 6.1 Gener al Heater s are designed f or installation abo v e 2.5 m. These heat ers m u st be inst alled w ithin the heat ed space. D u ct deli v er y s y stems ar e not per mit ted w ith axial f ans. W hen handling or s u ppor ting[...]

  • Page 17

    SECTION 6: H EATER I NSTALLATION 1 1 of 42 Fi g ur e 4: Suspension Methods Existing cabinet scr e w s m u st be r e- u sed. Cone P oint Set Pin Windo w Clamp Unistrut 1 0 mm Steel Drop R od Nut W asher Riv Nut Suppor t P oints Ensure all suspension har dware is tor qued to a minimum of 27 Nm (20 f t lbs). NO TE: For vertical installations, use the [...]

  • Page 18

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 12 o f 4 2 Fi g ur e 5: Shelf Mountin g and Han g in g Suspension Hard w are pr o v id ed to constr u ct mo u nting brac k et assemb ly only . Fi g ur e 6: V ertical Louvr es (Optional) F or models 15 and 22, horiz ontal lo uv res ar e re- u sed. Shelf Mounting Brack ets [...]

  • Page 19

    SECTION 7: F LUE I NSTALLATION 1 3 of 42 SECTION 7: FLUE INSTALLATION 7 .1 Flue Installation 7. 2 C h a n g in g Flue and A ir Intake Orientation The heat er is sold w ith hor izont al fl u e and fre sh air connections as standar d. If v ertical fl u e and fresh air connections ar e req u ir ed, f ollo w the instr u ctions on P age 39, Section 16.4[...]

  • Page 20

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 14 o f 4 2 Fi g ur e 7: Flue and R oof Detail Fi g ur e 8 : V ertical and Horizontal Flue T ermination - T ype B 22 Appliance Roof F lue T erminal Metal Sleeve Masterflash Soaker F lashing or Rain Collar . F lue 25 mm Air Gap to Combustib le Mater ial W all T erminal Flue[...]

  • Page 21

    SECTION 7: F LUE I NSTALLATION 1 5 of 42 Fi g ur e 9: V ertical and Horizontal Flue T ermination - T ype C 12 C 32 & C 62 Appliances W all Plate W all T erminal Flue Roof T erminal Flue Air Int ake Air Int ake Manif old Manif old V er tical Option Plastic Cup Masterf lash Horizontal Option Remo ve Int er nal Wir e Mesh Remo ve Int er nal Wir e [...]

  • Page 22

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 16 o f 4 2 SECTION 8 : AIR SUPPLY 8 .1 R oom Sealed Installa tion When installed as a r oom sealed heater , the air f or comb u stion is dr a w n in fr om o u tside the b u ilding. It is impor tant to ens u r e that there is adeq u at e v entilation t o pro v ide air for [...]

  • Page 23

    SECTION 9: G AS P IPE W ORK 1 7 of 42 SECTION 9: GAS PIPE W ORK It is impor tant that the g as s u pply pipe and the electrical conn ections do not s u ppor t any of the heat er’ s w eight. A gas met er is connected t o the ser v ice pipe by the gas s u pply company . An existing met er sho u ld be check ed, pref erab ly by the compan y , to ens [...]

  • Page 24

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 18 o f 4 2 Fi g ur e 1 0: Gas Connection w ith Stainless Steel Fle x Connect or[...]

  • Page 25

    SECTION 1 0: W IR ING AND E LECTRI CAL I NFOR MATION 1 9 of 42 SECTION 1 0: W IRING AND ELECTR ICAL INFORM ATION 1 0.1 Electr ical Suppl y All heater s need a constant 230 V 50 Hz single phase s u pply connect ed to t er minals L, N & Ear th. P olarity "L & N" m u st be corr ect. The v olt age bet w een ne u tral and e ar th sho u[...]

  • Page 26

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 20 of 42 1 0.3 CTCU A Wir in g Dia g ram (Models 7 -32) NO TE: If any of the or iginal w ir e s u pplied w ith the heat er m u st be r eplaced, it m u st b e replaced w ith w ir ing mater ial ha v ing a t emperat u r e rating of at least 1 05° C a nd 600 v olts.[...]

  • Page 27

    SECTION 1 1: C OMMISSIONING 21 of 42 SECTION 1 1: COMMISSIONING Gas F ire d Heater Installation C ode and Ann u al Insp ections: All installation and ser v ice of ROBER TS GORDON ® eq u ipment m u st b e perf orm ed b y a contract or q u alif ied in the installation and ser v ice of eq u ipment sold and s u pplied b y R ober ts-Gordon and conf or [...]

  • Page 28

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 22 of 42 1 1 .4 Be g in Commissi onin g 1 1 .4.1 Befor e Operatin g the Heater T o ens u re that all the contr ols ar e in saf e w orking order , operate the heate r f or the f irst time w ith the isolating g as v al v e t u r ned of f. 1. T u rn off the gas isola ting v [...]

  • Page 29

    SECTION 1 1: C OMMISSIONING 23 of 42 Fi g ur e 1 2: Gas V alve f or Heater (Models 7 - 32) 1 1 .4.2 Commissionin g the Gas V alv es (all g ases) 1 1 .4.2.1 Chec k Burner Gas Pr essure 1 . Loosen the scr e w co v er of the o u tlet (b u rner) pr ess u r e test point and connect a manomet er . 2. With the b u r ner fir ing, meas u r e the press u r e[...]

  • Page 30

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 24 of 42 11 . 8 Complete the Commissionin g Ens u r e that all co v ers ar e fit t ed corr ectly and all test points ar e pr operl y sealed. 1 1 .9 Instruction t o the User Explain the controls of the heate r to the u ser incl u ding ho w to t u rn it on and of f, u sing [...]

  • Page 31

    SECTION 1 2: U SER I NSTRUCTIONS 25 of 42 SEC TIO N 12: USER INSTRUCTIONS 1 2.1 User Instructions The CTCU heat ers ar e f u lly a u tomatic and oper ate from the e xternal controls f it ted on sit e. The only u ser controls at th e heater a re the: B u rner Lock o u t Reset B u t t on: See P age 26, Section 1 2.3.2 Limit Thermostat Reset B u t t o[...]

  • Page 32

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 26 of 42 1 2.3.2 Limit Thermostat The limit thermostat is located insid e the access door of the heat er . See P age 38, Section 16.3 . This control p rot ects the heat e x changer against o v erheating. 1 2.3.3 Burner Lock out Reset But t on The r ed w arning light at th[...]

  • Page 33

    SECTION 1 3: S ERVICING 27 of 42 SECTION 1 3: SER VICING 1 3.1 Ser vicin g Instructions Af ter commissioning , the heater w ill r eq u ir e mainten ance to be ca rried o u t ann u ally . If the heat er is u sed in a dir t y or d u sty area, mor e freq u ent mainten ance ma y be necessar y . Installation, ser v ice and ann u al inspection of heat er[...]

  • Page 34

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 28 of 42 heat e x changer . Look f or signs of o v erheating at the front t u bes w hich ma y indicat e b u rner o v er f iring or pers istently lo w air flo w s. 1 3.5 Gas Control V alv e Maintenance No reg u lar mainten ance is r eq u ir ed on these de v ices. T o chang[...]

  • Page 35

    SECTION 1 3: S ERVICING 29 of 42 Burner Observ ation W indow Make s u r e it is clean and free of cr acks or holes . Clean and r eplace as re q u ired. Flue Blow er Scroll, Wheel and Motor Comp resse d air or a v ac uu m cleaner ma y be u sed to clean d u st and dir t. Inshot Bur ners and Orif ices Clear obstr u ctions (e v en spider w ebs w ill ca[...]

  • Page 36

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 30 of 42 SECTION 1 4 : CON VER SION BETWEEN GASES 1 4.1 General Con v er sion bet w een g a ses w ill r eq u ire a change of b u rner injector s and the gas v al v e r e-commissioning to th e ne w con ditions. 1 4.2 Burner Con ver sion Con v er sion of the b u rner assemb[...]

  • Page 37

    SECTION 1 5: T ROUB LESHOOTING 31 of 42 SEC TION 15: T R OUBLESHOOTING D ANGER Electrical Shoc k Hazard Disconnect electric bef ore service . Heater m ust be properl y grounded. Failur e to f ollow these instr uctions can result in death or electrical shoc k. F ire Hazar d Keep all f lammable objects, liquids and vapor s the minimum requir ed clear[...]

  • Page 38

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 32 of 42 1 5.1 General Fo r yo u r safety and optim u m heat er perf or mance , u se only ROBER TS GORDON ® replaceme nt par ts. Conduct Commissionin g pr ocedur e as shown o n P age 21, Section 1 1 .[...]

  • Page 39

    SECTION 1 5: T ROUB LESHOOTING 33 of 42 1 5.2 T r oubleshootin g Fo r Au to m a t i c I g nition Burner S yst ems For y o u r safety and optim u m heat er performance, u se only R OBER TS GORDON ® r eplacement par ts. Conduct Commissionin g pr ocedur e as shown on P age 21, Section 1 1 .[...]

  • Page 40

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 34 of 42 1 5.3 T r oubleshootin g f or Flame Supervision S yst em 1 5.4 T r oubleshootin g for Solenoi d V alv es NO TE: Minim u m flame pr obe c u rrent 1 µA DC . T o meas u re f lame c u rrent, connect a 0 - 5 0 µA DC meter in ser ies w ith the f lame probe . If the m[...]

  • Page 41

    SECTION 1 5: T ROUB LESHOOTING 35 of 42 1 5.5 T r oubleshootin g for Main Fan Fo r yo u r safety and optim u m heat er performance, u se only gen u ine R OBERTS GORDON ® r eplacement par ts. Conduct Commissionin g pr ocedure as sho wn on P age 21, Section 1 1 .[...]

  • Page 42

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 36 of 42 SECTION 1 6: REMOV AL AND REPLACEMENT P AR TS See w arnings and not es on P age 27 , Section 13 b efo re re m o v ing or replacing parts. Burner Componen ts All ser v iceable b u r ner par ts are accessed b y the door on the r ight side of the heater . Use a scre[...]

  • Page 43

    SECTION 1 6: R EMOV AL AND R EPLACEMENT P ARTS 37 of 42 1 6.2 Burner Compartment 1 6.2.1 Burner Inject ors Remo ve f lexi b le air duct from spigot V iew ing por t f or flame pr o b e Flame P ro b e Burner Compartment Co ver Ignition Electrode Remo ve scr ews and pull of f b ur ner cov er The b u rner compar tment is a sealed compar tment. F ollo w[...]

  • Page 44

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 38 of 42 1 6.3 I g nition Electrode and Flame P robe Burners .1 20 (3 mm) spark gap Ignition Electrode Burner Compartment Front Views Limit Thermostat Ignition Electrode Flame P robe F an Thermostat Flame P robe Burners Description Part Number Spark Electrode 90427 41 1 A[...]

  • Page 45

    SECTION 1 6: R EMOV AL AND R EPLACEMENT P ARTS 39 of 42 1 6.4 Flue Fan V ertical Installation (Models 7 - 1 5) IT IS IMPOR T ANT THA T ONL Y THE CORRECT FLUE F AN SPECIFIED FOR EA CH MODEL TYPE IS USED WHEN REPLA CING THESE ITEMS. Ca r r y o u t a c ommission aft e r w orking on or changing a f l u e f an. See P age 25, Section 1 2 . MODEL CTCU-7 C[...]

  • Page 46

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 40 of 42 1 6.5 Flue Fan V ertical Installation (Models 22 - 32) IT IS IMPOR T ANT THA T ONL Y THE CORRECT FLUE F AN SPECIFIED FOR EA CH MODEL TYPE IS USED WHEN REPLA CING TH ESE ITEMS. Ca r r y o u t a c ommission aft e r w orking on or changing a f l u e f an. See P age [...]

  • Page 47

    SECTION 1 6: R EMOV AL AND R EPLACEMENT P ARTS 41 of 42 1 6.6 Pr essure S witch P u ll of f 3 w a y connector . Spring open plastic clips of mo u nting cradle. R eplace w ith corr ect t ype of press u re s w itch f or model. The pr ess u re s w itch es are colo u r coded f or each press u re s e t t in g. Ca r r y o u t a c ommission aft e r w orki[...]

  • Page 48

    COMBA T ® CTCU U NIT H EATER S I NSTALLATION O PERATION AND S ERVICE M ANUAL 42 of 42 1 6.7 I g nition Control This contr ol is mo u nted at the br acke t plate . P u ll o u t the thr ee cable conne ctor s. P u ll o u t ignition cable , ignition ear th and flame p robe ca ble no ting their positions. Locate d behind the brac ket ignition control a[...]

  • Page 49

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  • Page 50

    W ARNING At tach this infor mation to the wall near the R OBERTS GORDON ® heater Read the Installation, Commissioning, Oper ation and Service Manual thoroughl y befor e installation, operation or service. OPERA TING INSTR UCTIONS 1 . STOP! R ead all safety instructions on this information sheet. 2. Open the manual gas val ve in the heat er supply [...]