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FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier's
instructions.
8. If you cannot reach your gas
supplier, call the Fire Department.
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapours the minimum required
clearances to combustibles away from
heater.
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
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.
Installation must be done by a registered installer/
contractor qualified in the installation and service
of gas-fired heating equipment or your gas supplier.
© 2017 Combat HVAC Limited
Combat
Tubular Unit Heaters
Installation, Commissioning,
Operation & Service Manual
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.
Keep this manual in a safe place in order to provide
your service technician with necessary information.
Combat HVAC Limited
Unit 20, Red Mill Trading Estate
Rigby Street, Wednesbury
West Midlands, WS10 0NP
Telephone: +44(0)121 506 7700
Fax: +44 (0)121 506 7701
Service Telephone: +44 (0)121 506 7709
Service Fax: +44 (0)121 506 7702
E-mail: uksales@combat.co.uk
E-mail:export@combat.co.uk
www.combat.co.uk
Model CTU
75 to 115
Installer
Owner
P/N X408UK Orig. 09/14
®
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Table of Contents
Troubleshooting
Related Manuals for COMBAT CTU-90
Summary of Contents for COMBAT CTU-90
- Page 1 Rigby Street, Wednesbury West Midlands, WS10 0NP Telephone: +44(0)121 506 7700 Fax: +44 (0)121 506 7701 Service Telephone: +44 (0)121 506 7709 Service Fax: +44 (0)121 506 7702 E-mail: uksales@combat.co.uk E-mail:export@combat.co.uk www.combat.co.uk © 2017 Combat HVAC Limited P/N X408UK Orig. 09/14...
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Page 3: Table Of Contents
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 Combat HVAC Limited. Printed in U.K. - Page 5 TABLE OF FIGURES Figure 1: Side and Back Panel Label Placement...... 2 Figure 2: Side Panel Label Placement........3 Figure 3: Installation Clearances and Clearances to Combustibles ............. 6 Figure 4: Suspension Methods ..........13 Figure 5: Flue and Roof Detail ..........14 Figure 6: Vertical and Horizontal Flue Termination - Type B Appliance ..........
- Page 7 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.
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Page 8: Section 1: Heater Safety
This heater is designed for heating non-domestic For additional copies of the Installation, Operation and Service Manual, please contact Combat HVAC indoor spaces. Do not install in domestic spaces. These instructions, the layout drawing, local codes Limited. -
Page 9: Figure 2: Side Panel Label Placement
SECTION 1: H EATER AFETY Figure 2: Side Panel Label Placement Description Part Number Lighting Instruction Label 91040002 Remote Reset Label 91040019 Terminal Label 91130301 Wiring Diagram Label 75-115 91040004 3 of 46... -
Page 10: Section 2: Installer Responsibility
• To provide access to burners for servicing. • To provide the owner with a copy of this Combat cannot be responsible for ensuring that all installation, commissioning, operation and appropriate safety measures are undertaken prior to service manual. -
Page 11: Section 3: Clearances To Combustibles
SECTION 3: C LEARANCES TO OMBUSTIBLES SECTION 3: CLEARANCES TO COMBUSTIBLES • Maintain clearances from swinging and over- head doors, overhead cranes, vehicle lifts, parti- WARNING tions, storage racks, hoists, building construction, etc. • In locations used for the storage of combustible materials, signs must be posted to specify the maximum permissible stacking height to main- tain required clearances from the heater to the... -
Page 12: Figure 3: Installation Clearances And Clearances To Combustibles
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL Figure 3: Installation Clearances and Clearances to Combustibles Installation Clearances Clearances to Combustibles Roof Terminal 15 cm 15 cm Intake 50 cm 50 cm** Flue Wall Terminal 60 cm 30 cm 2.5 - 3.5 m*... -
Page 13: Section 4: Critical Considerations
SECTION 4: C RITICAL ONSIDERATIONS SECTION 4: CRITICAL CONSIDERATIONS 4.1 Ventilation 4.3 Electrical Supply WARNING DANGER Carbon Monoxide Hazard Electrical Shock Hazard Heaters may be installed vented or unvented. Disconnect electric before service. Vented heaters must be vented outdoors. Heater must be properly grounded. Unvented heaters must be installed in buildings with ventilation rates as per Failure to follow these instructions can result... -
Page 14: Section 5: Specifications
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 5: SPECIFICATIONS 5.1 CTUA Top View Heater must be supported at these points from above or below. 4 x M10 Captive Nuts Provided Support Centers End View Rear View... -
Page 15: Ctub, Ctuc And Ctud
SECTION 5: S PECIFICATIONS 5.2 CTUB, CTUC and CTUD Dimension Data - CTUB, CTUC and CTUD Model 1076 1076 1076 1076 CTUB Depth (42.4) (42.4) (42.4) (42.4) (in) 1100 1100 1380 1380 CTUB Height (43.3) (43.3) (54.3) (54.3) (in) 1100 1100 1431 1431... -
Page 16: General Technical Data Table
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 5.3 General Technical Data Table Model CTU-75 CTU-90 CTU-100 CTU-115 CTUA With Axial Fan Total Electrical Load Run Current Start Current Air Flow 7500 7500 11,000 11,000 [52.3] [52.3] [52.3] [52.3]... -
Page 17: Technical Data Table
SECTION 5: S PECIFICATIONS 5.4 Technical Data Table Appliance Category II 2H/L 3B/P Model CTU-75 CTU-90 CTU-100 CTU-115 Heat Input 92.2 Gross CV (Btu/h) x (1000) 90.6 91.0 91.5 91.7 Heat Input Net CV (Btu/h) x (1000) Approximate Heat Output... -
Page 18: Section 6: Heater Installation
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 6: HEATER INSTALLATION 6.1 General 6.5 Suspension and Shelf Mounting Heaters are designed for installation above 2.5 m. WARNING These heaters must be installed within the heated space. Duct delivery systems are not permitted with axial fans. -
Page 19: Figure 4: Suspension Methods
SECTION 6: H EATER NSTALLATION Figure 4: Suspension Methods Insure all suspension hardware is torqued to a minimum Unistrut Channel Nut of 27 Nm (20 ft lbs) Washer 10 mm Steel Drop Rod Cone Point Set Pin Window Clamp 10 mm Unistrut Steel Drop Rod... -
Page 20: Section 7: Flue Installation
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: FLUE INSTALLATION 7.1 Flue Installation Page 15, Figure 7. The joints between the flue terminal and the roof or wall must be properly WARNING sealed. If the flue passes through a wall or ceiling of... -
Page 21: Figure 6: Vertical And Horizontal Flue Termination
SECTION 7: F NSTALLATION Figure 6: Vertical and Horizontal Flue Termination - Type B Appliance Roof Terminal Masterflash Metal Sleeve (25 mm air gap to Combustible Material) Flue Air Intake Terminal Cover Vertical Option 90° Bend Masterflash Flue Horizontal Option Wall Terminal Figure 7: Vertical and Horizontal Flue Termination - Type C... -
Page 22: Section 8: Air Supply
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 8: AIR SUPPLY 8.1 Room Sealed Installation 8.3 Building Ventilation When installed as a room sealed heater, the air for Where ventilation is required, air must be taken from combustion is drawn in from outside the building. -
Page 23: Section 9: Optional Heater Configurations
The fan motor, or its control, must contain a method Contact Combat HVAC Ltd. Design Department of overload protection. When installed remote from for recommendations regarding duct resistance the heater, the fan must be supplied via a local and design. -
Page 24: Section 10: Gas Pipe Work
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 10: GAS PIPE WORK • The gas supply pipe is adequately sized to carry the total volume of gas for the complete installation. • An isolating valve and union connection should be used and fitted into the supply adjacent to the heater. -
Page 25: Figure 10: Gas Connection With Stainless Steel Flex Connector
SECTION 10: G Figure 10: Gas Connection with Stainless Steel Flex Connector 19 of 46... -
Page 26: Section 11: Wiring And Electrical Information
11.2.2 Positioning Room Thermostats or Combat ® Control Disconnect electric before service. A room thermostat or Combat ® control should be mounted on a wall or column at a height of Heater must be properly grounded. approximately 1.5 metres from the floor to measure the ambient temperature. -
Page 27: Ctua Wiring Diagram (Models 75-115)
SECTION 11: W IRING AND LECTRICAL NFORMATION 11.3 CTUA Wiring Diagram (Models 75-115) NOTE: 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. -
Page 28: Ctub/C Wiring Diagram (Models 75-115)
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 11.4 CTUB/C Wiring Diagram (Models 75-115) NOTE: Unused speed setting wires for the centrifugal fan must be isolated and insulated. If any of the original wire supplied with the heater must be... -
Page 29: Ctud Wiring Diagram (Models 75-115)
SECTION 11: W IRING AND LECTRICAL NFORMATION 11.5 CTUD Wiring Diagram (Models 75-115) NOTE: For external fan wiring, See Page 24, Section 11.6. 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°... -
Page 30: Ctud External Motor Alternative Wiring & Optional Thermostat/Time Switch
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 11.6 CTUD External Motor Alternative Wiring & Optional Thermostat/Time Switch 24 of 46... -
Page 31: Section 12: Commissioning
Combat and conform to all 12.1.2 Electrical Checks requirements set forth in the Combat ®... -
Page 32: Begin Commissioning
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 12.4 Begin Commissioning 2. Using the installed external control, turn on the burner. The automatic sequence will now begin 12.4.1 Before Operating the Heater as described on Page 26, Figure 11. -
Page 33: Combustion Testing
SECTION 12: C OMMISSIONING Figure 12: Gas Valve for Heater (Models 75 - 115) Plug for Main Gas Valve Regulator (Under Cover) Plug for Main Safety Gas Valve Inlet Pressure Gas Inlet Gas Outlet Outlet Pressure 12.4.2 Commissioning the Gas Valves (all gases) 3. -
Page 34: External Controls
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 12.7 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’... -
Page 35: Section 13: User Instructions
SECTION 13: U NSTRUCTIONS SECTION 13: USER INSTRUCTIONS DANGER Electrical Shock Hazard Disconnect electric before service. Heater must be properly grounded. Failure to follow these instructions can result in death or electrical shock. WARNING Fire Hazard Explosion Hazard Burn Hazard Cut/Pinch Hazard Keep all flammable Turn off gas supply to... -
Page 36: Common User Controls
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 13.3 Common User Controls 4. The thermostat limit thermodisc may have operated. This may be caused by an interrup- 13.3.1 Thermostat Limit Thermodisc tion of the electrical supply or failure of the Press to reset distribution fan. -
Page 37: Section 14: Servicing
SECTION 14: S ERVICING SECTION 14: SERVICING WARNING DANGER Electrical Shock Hazard Explosion Hazard Burn Hazard Cut/Pinch Hazard Turn off gas supply to Allow heater to cool Wear protective gear Disconnect electric heater before service. before service. during installation, before service. operation and service. -
Page 38: Heat Exchanger Maintenance
ANUAL air flow for each model can be found on Page 10, Replace faulty gas valves with genuine replacement parts sold and supplied by Combat. Section 5.3. For CTUC models, the fans may be accessed via the removable panels in the top, bottom and sides of 14.6 Flue Fan... - Page 39 See Page 4, Section 2.1. Safety Labels Product safety signs or labels should be replaced by the product user when they are no longer legible. Please contact Combat HVAC Limited of your Combat ® independent distributor to obtain replace-ment signs or labels. See Page 2, Figure 1 through Page 3, Figure 2.
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Page 40: Section 15: Conversion Between Gases
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 15: CONVERSION BETWEEN GASES 15.1 General Conversion between gases will require a change of burner injectors and the gas valve re-commissioning to the new conditions. 15.2 Burner Conversion Conversion of the burner assembly from one gas to the other is the same for all types of heaters. -
Page 41: Section 16: Troubleshooting
SECTION 16: T ROUBLESHOOTING SECTION 16: TROUBLESHOOTING DANGER Electrical Shock Hazard Disconnect electric before service. Heater must be properly grounded. Failure to follow these instructions can result in death or electrical shock. WARNING Fire Hazard Explosion Hazard Burn Hazard Cut/Pinch Hazard Keep all flammable Turn off gas supply to Allow heater to cool... -
Page 42: General
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 16.1 General START Are gas & electrical Turn on supplies. supplies on? Is Red lockout Use 15.2 to test burner. warning light on? Check limt thermostat; With external controls on, Use 15.2 to test burner. -
Page 43: Troubleshooting For Automatic Ignition Burner Systems
SECTION 16: T ROUBLESHOOTING 16.2 Troubleshooting For Automatic Ignition Burner Systems To measure flame current, connect a 0 - 50 µA DC meter in series with the flame probe. If the meter reads negative values, then reverse the test leads. Start Are gas &... -
Page 44: Troubleshooting For Flame Supervision System
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 16.3 Troubleshooting for Flame Supervision System NOTE: Minimum flame probe current 1 µA DC. 16.4 Troubleshooting for Solenoid Valves START Is 230 V at the valve terminals at the Fault elsewhere appropriate time. -
Page 45: Section 17: Removal And Replacement Parts
DANGER Electrical Shock Hazard Explosion Hazard Carbon Monoxide Hazard Fire Hazard Use only genuine Combat ® replacement parts per this installation, operation and service manual. Failure to follow these instructions can result in death, electric shock, injury or property damage. -
Page 46: Burner Compartment
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL Replace in reverse order. Verify that the gas flow Page 27 , Section 12.4.2. direction of the valve is correct. Use a minimum IT IS IMPORTANT THAT ONLY THE CORRECT amount of gas seal on the thread joint. - Page 47 Remove manifold screws and pull Injectors out manifold Manifold Unscrew Injectors Burner venturi Burner Screws Marking MODEL CTU-75 CTU-90 CTU-100 CTU-115 Injector Quantity Natural Gas (G20) and (G25) Injector size mm Ø 2.71 2.71 2.71 2.71 in Ø 0.1067 0.1067 0.1067 0.1067...
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Page 48: Ignition Electrode And Flame Probe
COMBAT ® CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 17.3 Ignition Electrode and Flame Probe Burners Thermostat Limit Thermodisc Flame Flame Probe Probe Remove all burner compartment screws to remove the burner Remove compartment and Screw access the “Front View” . -
Page 49: Flue Fan
Vent Box Ensure sealed joints. Screws Ensure mounting plate orifice is Gasket clear and not obstructed. Mounting Plate to Flue Fan Screws MODEL CTU-75 CTU-90 CTU-100 CTU-115 Flue Fan AO Smith AO Smith AO Smith Torin DSF JFIG098NS JFIG098NS JFIG098NS... -
Page 50: Pressure Switch
The pressure switches are colour coded for each pressure setting. Carry out a commission after working on or changing a pressure switch. See Page 25, Section Pressure Switch CTU-75 CTU-90 CTU-100 CTU-115 RG P/N 90439811 90439807... -
Page 51: Ignition Control
• Check that the fan blades are free to rotate • Use only genuine replacement parts sold and before turning on the power to the fan. supplied by Combat. • Strictly comply with the colour code of the fan The three speed winding connections are: wires to ensure correct operation. -
Page 52: Fan Data
• Set all fans to operate at the same speed. Figure 14: Centrifugal Fan Orientation 17.9 Fan Data MODEL CTU-75 CTU-90 CTU-100 CTU-115 Axial Fan Type Axial Fan Axial Fan Axial Fan... - Page 54 Installation Code and Annual Inspections All installation and service of Combat equipment must be performed by a contractor qualified in the installation of equipment sold and supplied by Combat HVAC Limited and conform to all requirements set forth in the Combat manuals and all applicable governmental authorities pertaining to the installation, service, operation and labeling of equipment. To help facilitate optimum performance and safety Combat HVAC Limited recommends that a qualified contractor conduct, at minimum, annual inspections of your Combat equipment and perform service where necessary, using only replacement parts sold and supplied by Combat HVAC Limited.