Roberts Gorden CTU 22 TO 115 manual

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. Leav e the build ing. 6. Immediatel y call your local gas supplier af ter leaving the b uilding. F ollow the gas supplier  s instructions. 7 . If you cann[...]

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© 2007 R ober ts-Gor don, LLC All rights reserved. No part of this work cover ed by the cop yr ights herein ma y be repr oduced or copied in any f or m or by any means - graphic, electronic, or mechanical, including photocop ying, recor ding, taping or information storage and retriev al syst ems - without the writt en per mission of Rober ts-Gordo[...]

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TABLE OF FIGURES Figur e 1: Installation Clearances and Clearances to Comb ustibles ....... .............. .............. .............. ............ 4 Fi gure 2: Suspension Methods ............................ .............. ....... 9 Fi gure 3: Flue and R oof Detail ..................... ................. .......... 1 0 Fi gure 4: A ir Intake T e[...]

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1 P roduct Appr ov al ROBERTS GORDON ® appliances have been tested and CE certified as complying with the essential requirements of the Gas Appliance Directive, the Low V oltage Directive, the Electromagnetic Compatibility Directive and the Machinery Directive for use on natural gas and LPG when installed, commissioned and maintained in accordance[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 2 SECTION 1: HEATER SAFETY Y our Saf et y is Impor t ant t o Us! This s ymbol is used thr oughout the manual t o notify y ou of possib le fir e, electrical or burn hazards . Please pay special at tention when r eading and f ollowing the w ar nings in these sections. Instal[...]

SECTION 3: C RITICAL C ONSIDERATIONS 3 SECTION 3: CRITICAL CONSI DERATIONS 3.1 Basic Inf ormation CTU heate rs ha ve aut omatic ignition burners f or ON/OFF operation only . 3.2 Location and Suspension All models: • Must be inst alled indoors . • Must be inst alled in a le v el position. • Ma y be mount ed on a shelf of non-comb ustible mater[...]

W ARNING 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 follo w these instructions can result in death, injury or property damage. COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UA[...]

SECTION 4: S PECIF ICATIONS 5 SECTION 4: SPECIFICATIONS 4.1 CTU A A B Rear View End View Z 646 168 Gas Supply F G H T op 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 Model 22 30 35 40 50 60 75 90 100 115 A Width m[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 6 4.2 CTUB, CTUC and CTUD 11 5 11 5 End View CTUB/C (All Models) 11 5 End View CTUC (All Models) End View CTUD (All Models) F ront View CTUD (And other models fit ted with air outlet spigots) N N 646 P N M L N K 1 440 679 646 Model 22 30 35 40 50 60 75 90 100 115 K CTUB De[...]

SECTION 4: S PECIF ICATIONS 7 4.3 Gener al T echnica l Data T able Model CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CT U-90 CTU-1 0 0 CTU-1 15 CTU A With Axial Fan T otal Electrical Load W 21 0 21 0 21 0 21 0 41 5 415 51 0 51 0 74 5 74 5 Run Cur ren t A 1. 0 1. 0 1. 0 1. 0 1. 7 2 1. 7 2 1. 9 1. 9 3.2 3.2 Star t Current A 1. 4 1. 4 1. 4 1. 4 2[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 8 4.4 T echnic al Data T able Appliance C ategor y II 2H/L 3B/P Model CTU-22 CTU-30 CTU-35 CTU-40 CTU-50 CTU-60 CTU-75 CTU-90 CTU-1 0 0 CTU-1 15 Heat Input Gross CV kW (Btu/h) x (1 000) 27 93 33 11 3 39 13 3 48 16 3 61 21 0 70 238 95 324 111 378 11 9 405 13 4 459 Heat Inpu[...]

SECTION 5: H EATER I NSTALLATION 9 SECTION 5: HEATER INSTALLATION 5.1 Gener al Heater s are designed f or installation abov e 2.5 m. These heat ers must be inst alled within the heat ed space. D uct delivery sy stems ar e not per mit ted wi th axial f ans. 5.2 Handling All CTU heater s are supp lied secur ed to a w ooden pallet and shrink wrapped. [...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 10 SECTION 6: FLUE INSTALLATION 6.1 Flue Installati on W ARNING 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 follo w these inst[...]

SECTION 6: F LUE I NSTALLATION 11 F igur e 5: V ertical and Horizontal Flue T ermination - T ype B 22 Appliance W all T erminal Air Int ake T erminal Cov er Flue Masterf lash Masterf lash Roof T erminal V er tical Option Horizontal Option 90° Bend Flue Metal Slee ve (25 mm air gap t o Comb ustible Mat er ial) F igur e 6: V ertical and Horizontal F[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 12 SECTION 7: AIR SUPPLY 7 .1 Room Se aled Installation When installed as a r oom sealed heater , the air f or combustion is dra wn in fr om outside the b uilding. It is impor tant to ensur e that there is adequate v entilation t o provide air f or the distr ibution f an/s[...]

SECTION 8: O PTIONAL H EAT ER C ONFIGUR ATIONS 13 SECTION 8: OPTIONAL HEATER CONF IGURATIONS 8.1 Distrib ution Duct W ork f or CTUB, CTUC and CTUD Heater s CTUC heater s hav e the fans enclosed so that the heat er ma y be connected t o inlet ducting. CTUD heater s are supplied w ith inlet and outlet duct spigots f or mounting the heater int o a cus[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 14 SECTION 9: GAS PIPING W ARNING Fire Hazard Connect gas supply according to Figure 9 . Gas can lea k if not installed properly . Failure to follo w these instructions can result in death, injury or property damage. It is impor tant that the g as suppl y pipe and the elec[...]

SECTION 1 0: W IR ING AND E LECTRI CAL I NFOR MATION 15 SECTION 1 0: W IRING AND ELECTR ICAL INFORM ATION 1 0.1 Electr ical Supply All heater s need a constant 230 V 50 Hz single phase supply connect ed to t er minals L, N & Ear th. P olarit y "L & N" must be correct. The volt age bet ween neutral and earth should be 0 and ne ver [...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 16 1 0.3 CTU A W iring Diagr am (Models 22-60) IGNITION MODULE BLACK Plug in Connection to Gas V alve S4565C 1017 Control Honeywell BLACK SENSE IGNITION 230 V 1 Ø 50 Hz IGNITION MODULE LOCKOUT GAS V AL VE RUN 11 12 7 9 10 8 5 64 SITE WIRING 2 3 1 E N L 1 2 3 7 8 BLUE BROW[...]

SECTION 1 0: W IR ING AND E LECTRI CAL I NFOR MATION 17 1 0.4 CTU A W iring Diagr am (Models 75-1 1 5) 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 NCP(2) Pressure Switch Detail NOP(3) C [...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 18 1 0.5 CTUB/C W iring Dia gr am (Models 22-40) IGNITION MODULE BLACK Plug in Connection to Gas V alve S4565C 1017 Control Honeywell BLACK SENSE IGNITION 230 V 1 Ø 50 Hz IGNITION MODULE LOCKOUT GAS V AL VE RUN 11 12 7 9 10 8 5 64 SITE WIRING 2 3 1 N L 1 2 3 7 8 BLUE BROW[...]

SECTION 1 0: W IR ING AND E LECTRI CAL I NFOR MATION 19 1 0.6 CTUB/C W iring Dia gr am (Models 50-60) B 7 8 9 A 5 4 6 RELA Y IGNITION MODULE BLACK Plug in Connection to Gas V alve S4565C 1017 Control Honeywell BLACK SENSE IGNITION 230 V 1 Ø 50 Hz IGNITION MODULE LOCKOUT GAS V AL VE RUN 11 12 7 9 10 8 5 64 SITE WIRING 2 3 1 N L 1 2 3 7 8 BLUE BROWN[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 20 1 0.7 CTUB/C W iring Dia gr am (Models 75-1 15) S 4563 C Honeywell MEDIUM BLUE L N E A B 4 5 6 7 8 9 COMBUSTION F AN BROWN RED NCP(2) Pressure Switch Detail NOP(3) C P(1) BLACK YELLOW WHITE PRESSURE SWITCH BLUE PINK GREY PURPLE LOCKOUT RUN GREEN/YELLOW BLACK WHITE YE[...]

SECTION 1 0: W IR ING AND E LECTRI CAL I NFOR MATION 21 1 0.8 CTUD W iring Dia gram (Models 22-60) IGNITION MODULE BLACK Plug in Connection to Gas V alve S4565C 1017 Control Honeywell BLACK SENSE IGNITION 230 V 1 Ø 50 Hz IGNITION MODULE LOCKOUT GAS V AL VE RUN 11 12 7 9 10 8 5 64 SITE WIRING 2 3 1 N L 1 2 3 7 8 BLUE BROWN BLUE MAINS FIL TER Pressu[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 22 1 0.9 CTUD W iring Dia gram (Models 75-1 1 5) S 4563 C Honeywell L N E COMBUSTION F AN NCP(2) Pressure Switch Detail NOP(3) C P(1) BLACK YELLOW WHITE PRESSURE SWITCH BLUE PINK GREY PURPLE LOCKOUT RUN GREEN/YELLOW BLACK WHITE YELLOW GREEN/YELLOW BROWN BLUE BROWN BLUE [...]

SECTION 1 0: W IR ING AND E LECTRI CAL I NFOR MATION 23 1 0.1 0 CTUD Exter nal Motor Alt ernati v e W iring 2A 230v LL L 1 2 3 N 400 V 3 Ø motor Three Phase Motor 400 V 50 Hz 3 Ø Supply NL 1 2 3 Contactor or Relay Overload protection must be provided at the motor or contactor . Room Thermostat Frost Thermostat 230 V 50 Hz T ime Switch RDW 1565 be[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 24 SECTION 1 1: COMMISSIONING Installation, se r vice, commissioning and ann ual inspection of the heat er must be done b y a contract or qualified in the installation and service of gas-f ired heating equipmen t. Read this man ual car efully befor e installation, commissi[...]

SECTION 1 1: C OMMISSIONING 25 F igur e 1 0: A utomatic Bur ner Control Bo x Sequence Burner sequence for Honeyw ell S4563 or S4565C Flame Signal Start Gas V alv e Ignition Spark Supply 230 V CL OSE DO WN RU N ST ART ts** Signals Output By Contr ol Flue F an P ressure Switch P C NO NC 30 Sec. Pur ge* *P urge time begins at pressure sw itch change o[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 26 F igur e 1 2: Gas V alve f or Heater (Models 75 - 1 15) Regulator (Under Cover) Inlet Pressure Gas Outlet Outlet Pressure Plug for Main Gas V alve Gas Inlet Plug for Main Safety Gas V alve 1 1 .4.2 Commissioning the Gas V alv es (all gases) 1 1 .4.2.1 Check Bur ner Gas [...]

SECTION 1 1: C OMMISSIONING 27 1 1 .7 External Contr ols External controls ma y include time s witch, r oom thermostat and frost thermostat. Operat e each control t o ensure that the y function correctly . Set the time s w itch (if fit t ed) and r oom ther mostat t o the users ’ r equirements . 1 1 .8 Complete the Commissioning Ensure t hat all c[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 28 SECTION 1 2: USER INS TRUCTIONS 1 2.1 User Instructions The CTU heat er s are fully automatic an d operat e from the e xternal controls f it t ed on sit e. The only user controls at th e heater a re the: Burner Lock out Rese t But ton: See P age 28, Section 1 2.3.2 Ther[...]

SECTION 1 2: U SER I NSTRUCTIONS 29 1 2.4.2 T o T urn the Heat er Of f Set the installed r emote contr ols to the “ OFF” position. The b ur ner wi ll turn off imme diately . The f an will continue t o r un f or a fe w minutes . T o rest ar t, tur n the control used abo ve t o “ ON” . 1 2.5 Simple Fault F inding Some possible r easons for t [...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 30 SECTION 1 3 : SERVICING 1 3.1 Ser vicing Instructions Af ter commissioning , the heater w ill requir e mainten ance t o be carried out annually . If the heat er is used in a dir t y or dusty are a, more frequent mainten ance ma y be necessar y . Installation, se r vice [...]

SECTION 1 4: C ON VERSION B ETW EEN G ASES 31 SECTION 1 4: CONV ERSION BETWEEN GASES 1 4.1 General Con ver sion bet w een gasses w ill requir e a change of burner injector s and the gas v alv e re-commissioning to th e new con ditions. 1 4.2 Burner Con ver sion Con ver sion of the burner assembly from one g as to the other is the same f or all type[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 32 SECTION 1 5: T R OUBLESHOOTING 1 5.1 General If prob lems persist, contact ROBERTS GORDON ® at T el: +44(0)1 21 506 7709 www .rg-inc.com Heater Operating TROUBLESHOO T ENDS. No Check for mis-wiring. Change time delay r elay . Check time delat r elay . Is there 230 V ac[...]

SECTION 1 5: T ROUB LESHOOTING 33 1 5.2 T r oubleshooting F or Aut omatic Ignition Bur ner S ystems Heater Operating TROUBLESHOO T ENDS. No T race fault in supervision sy stem. See Section 16.3. No Ye s Is red loc kout light on? No Is the flame curr ent at least 1 µAmp DC when the flame lights? Ignition control f ault y replace . See Section 1 5.6[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 34 1 5.3 T r oubleshooting f or Flame Supervision S yst em Repair or r eplace as necessary . Contr ol box f ault y . Replace with correct type. Use section 1 5.1 to trace the f ault. Heater Operating TROUBLESHOO T ENDS. No Repair or r eplace as necessary . Is inlet burner [...]

SECTION 1 6: R EMOV AL AND R EPLACEMENT P ARTS 35 SECTION 1 6: REMO VA L AND REPLACEMENT P AR TS See warnings and not es on P age 30, Section 1 3 bef ore remo ving or replacing par ts. Burner Componen ts All ser viceable b ur ner par ts ar e accessed by the door on the right side of the heat er . Use a scre wdriver t o tur n the latch 90°. See P a[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 36 1 6.2 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 Rubber Seal Ignition electrode The b ur ner co[...]

SECTION 1 6: R EMOV AL AND R EPLACEMENT P ARTS 37 1 6.3 Ignition Electrode and Flame P robe Description Part Number Spark Electrode 90427 41 1 Aut omatic Ignition Flame Pr o be 90439300 Burners (all models ex cept CTU-40) 92000000 Burners - CTU-40 9200000 1 Flame P robe Ignition Electrode Remo ve Sc rew Ignition Electrode Burners Flame P robe Burne[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 38 1 6.4 Flue Fan V ent Box Outlet Gasket Flue Fan V ent Box Screws Flue Adapter Flue Adapter to Flue Fan screws Rear Panel Hole Disconnect electrical connections at plug in tabs. Mounting Plate to V ent Box Screws Mounting Plate Gasket Air Plate Mounting Plate to Flue Fan[...]

SECTION 1 6: R EMOV AL AND R EPLACEMENT P ARTS 39 1 6.5 Pr essure S witch P ull of f 3 wa y connector . Spring open plastic clips of mounting cradle . Repla ce with correct type of pr essure s witch f or model. The pr essure s witches are colo ur coded f or each pressur e set ting. C ar b on M ono x ide H a z ard U se correct pressure switch specif[...]

COMBA T ® CTU U NIT H EATERS I NSTALLATION O PERATION AND S ERVICE M AN UAL 40 1 6.6 Ignition Control IT IS IMPOR T ANT THA T ONL Y THE CORRECT IGNITION CONTROL SPECIFIED FOR EA CH MODEL TYPE IS USED WHEN REPLA CING THESE ITEMS. 1 6.6.1 S4565C Models 22 to 60 This contr ol plugs ont o the g as val ve . P ull out 1 2 pin electrical connection. P ul[...]

SECTION 1 6: R EMOV AL AND R EPLACEMENT P ARTS 41 • Use only genuine ROBER TS GORDON ® replacement p ar ts. The thr ee speed winding connections ar e: Low speed: W hite N, R ed Liv e The other t wo w indings are "park ed" separat ely in spare t er minals. Medium speed: W hite N, Blue liv e. The other t wo w indings are "park ed&qu[...]

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W ARNING © 2007 Roberts-Gordon, LLC www .rg-inc.com Printed in U .S.A. P/N 91 040028 Rev B At tach this inf ormation t o 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 INS TRUCTIONS 1 . STOP! R ead all safety instruct[...]