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Tubular Unit Heaters
Installation, Commissioning,
Operation & Service Manual
Model CTU
22 to 115
Installer
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.
Owner
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Roberts-Gordon Europe Limited
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands WS10 7SH UK
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@rg-inc.com
Quality in Any Language™
E-mail: export@rg-inc.com
www.rg-inc.com
P/N X407UK Rev G 10/07
© Copyright 2007 Roberts-Gordon, LLC
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Summary of Contents for Roberts Gorden Combat CTU 22 to Combat 115
- Page 1 ® Tubular Unit Heaters Installation, Commissioning, Operation & Service Manual Model CTU 22 to 115 Installer 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. Owner Keep this manual in a safe place in order to provide your serviceman with necessary information.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1: Heater Safety............2 SECTION 12: User Instructions..........28 SECTION 2: Installer Responsibility ........2 12.1 User Instructions ............28 2.1 Clearances to Combustibles ........2 12.2 Heater Operation............28 2.2 Corrosive Chemicals............ 2 12.3 Common User Controls..........28 2.3 National Standards and Applicable Codes ....2 12.4 Lighting Instructions ..........28 SECTION 3: Critical Considerations ........ - Page 5 TABLE OF FIGURES Figure 1: Installation Clearances and Clearances to Combustibles............. 4 Figure 2: Suspension Methods ..........9 Figure 3: Flue and Roof Detail ..........10 Figure 4: Air Intake Terminal Cover......... 10 Figure 5: Vertical and Horizontal Flue Termination - Type B Appliance ..........
- Page 7 Product Approval...
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Page 8: Section 1: Heater Safety
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 1: HEATER SAFETY Your Safety is Important to Us! 2.2 Corrosive Chemicals 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 warnings in these sections. -
Page 9: Section 3: Critical Considerations
SECTION 3: C RITICAL ONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS 3.1 Basic Information 3.8 Flue CTU heaters have automatic ignition burners for Choose heater siting to allow for the proper location ON/OFF operation only. of the flue. Each heater must be fitted with an individual and correctly sized sealed flue system (See Page 10, Section 6). -
Page 10: Figure 1: Installation Clearances And Clearances To Combustibles
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL Figure 1: Installation Clearances and Clearances to Combustibles * Heaters may be mounted at a higher level if destratification fans and/or turn down nozzles are **80 cm is necessary to service heater. installed. -
Page 11: Section 4: Specifications
SECTION 4: S PECIFICATIONS SECTION 4: SPECIFICATIONS 4.1 CTUA Dimension Data - CTUA (All Models) Model 1075 1075 1075 1075 1075 1075 1327 1327 1327 1327 Width (in) (42.3) (42.3) (42.3) (42.3) (42.3) (42.3) (52.3) (52.3) (52.3) (52.3) 1100 1100 1345 1345 Height... -
Page 12: Ctub, Ctuc And Ctud
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 4.2 CTUB, CTUC and CTUD Dimension Data - CTUB, CTUC and CTUD Model 1026 1026 1026 1026 1026 1026 1076 1076 1076 1076 CTUB Depth (40.4) (40.4) (40.4) (40.4) (40.4) (40.4) (42.4) (42.4) -
Page 13: General Technical Data Table
SECTION 4: S PECIFICATIONS 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 Run Current 1.72 1.72 Start Current Air Flow 3800 4000 4000 4000 5500 5500 7500 7500... -
Page 14: Technical Data Table
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 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 (Btu/h) x (1000) Heat Input Net CV (Btu/h) x (1000) Approximate Heat Output... -
Page 15: Section 5: Heater Installation
SECTION 5: H EATER NSTALLATION SECTION 5: HEATER INSTALLATION 5.1 General 5.3 Shelf Mounting and Suspension 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. -
Page 16: Section 6: Flue Installation
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 6: FLUE INSTALLATION 6.1 Flue Installation Figure 3: Flue and Roof Detail The flue must terminate outside of the building. Flues and air intakes must be a fully sealed system and correctly sized for the model. -
Page 17: Figure 5: Vertical And Horizontal Flue Termination
SECTION 6: F NSTALLATION Figure 5: Vertical and Horizontal Flue Termination - Type B Appliance Figure 6: Vertical and Horizontal Flue Termination - Type C & C Appliances Model Concentric Flue Diameter 22-60 Cover (100mm) 150mm 75-115 Cover (130mm) 200mm... -
Page 18: Section 7: Air Supply
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: AIR SUPPLY 7.1 Room Sealed Installation 7.3 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 19: Section 8: Optional Heater Configurations
SECTION 8: O PTIONAL EATER ONFIGURATIONS SECTION 8: OPTIONAL HEATER CONFIGURATIONS 8.1 Distribution Duct Work for CTUB, CTUC and 8.1.1 CTUD Heaters CTUD Heaters For CTUD heaters, it is essential that the airflow in CTUC heaters have the fans enclosed so that the the duct system is at least that specified in the Data heater may be connected to inlet ducting. -
Page 20: Section 9: Gas Piping
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 9: GAS PIPING 9.1 Connections Connect the heater to the gas supply ensuring that the final connections are as follows: • Gas supply pipe work is run in medium or heavy gauge tubing in compliance with local and national codes. -
Page 21: Section 10: Wiring And Electrical Information
SECTION 10: W IRING AND LECTRICAL NFORMATION SECTION 10: WIRING AND ELECTRICAL INFORMATION 10.1 Electrical Supply 10.2.1 Burner Controls (Thermostat) All heaters need a constant 230 V 50 Hz single Controls to operate the burner must be voltage free contacts connected between terminals 2 & 3 of the phase supply connected to terminals L, N &... -
Page 22: Ctua Wiring Diagram (Models 22-60)
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 10.3 CTUA Wiring Diagram (Models 22-60) 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 23: Ctua Wiring Diagram (Models 75-115)
SECTION 10: W IRING AND LECTRICAL NFORMATION 10.4 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 24: Ctub/C Wiring Diagram (Models 22-40)
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 10.5 CTUB/C Wiring Diagram (Models 22-40) 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 replaced, it must be replaced with wiring material having a temperature rating of at least 105°... -
Page 25: Ctub/C Wiring Diagram (Models 50-60)
SECTION 10: W IRING AND LECTRICAL NFORMATION 10.6 CTUB/C Wiring Diagram (Models 50-60) 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 replaced, it must be replaced with wiring material having a temperature rating of at least 105°... -
Page 26: Ctub/C Wiring Diagram (Models 75-115)
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 10.7 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 replaced, it must be replaced with wiring material having a temperature rating of at least 105°... -
Page 27: Ctud Wiring Diagram (Models 22-60)
SECTION 10: W IRING AND LECTRICAL NFORMATION 10.8 CTUD Wiring Diagram (Models 22-60) NOTE: For external fan wiring, See Page 23, Section 10.10. 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 28: Ctud Wiring Diagram (Models 75-115)
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 10.9 CTUD Wiring Diagram (Models 75-115) NOTE: For external fan wiring, See Page 23, Section 10.10. 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 29: Ctud External Motor Alternative Wiring & Optional Thermostat/Time Switch
SECTION 10: W IRING AND LECTRICAL NFORMATION 10.10 CTUD External Motor Alternative Wiring & Optional Thermostat/Time Switch... -
Page 30: Section 11: Commissioning
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 11: COMMISSIONING Installation, service, commissioning and annual 11.1.2 Electrical Checks inspection of the heater must be done by a All pre-commission checks must be carried out contractor qualified in the installation and service of before commissioning the heater. -
Page 31: Figure 10: Automatic Burner Control Box Sequence
SECTION 11: C OMMISSIONING Figure 10: Automatic Burner Control Box Sequence If at any stage the flame fails, the control will go to "lockout". The red light will illuminate and the control will need to be manually reset before any further start attempt can be made. Figure 11: Gas Valve for Heater (Models 22 - 60) -
Page 32: Combustion Testing
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL Figure 12: Gas Valve for Heater (Models 75 - 115) 11.4.2 Commissioning the Gas Valves (all gases) 11.4.2.1 Check Burner Gas Pressure 11.5 Combustion Testing 1. Loosen the screw cover of the outlet (burner) The only adjustment to alter combustion performance is burner pressure. -
Page 33: External Controls
SECTION 11: C OMMISSIONING 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 Commissioning Ensure that all covers are fitted correctly and all test points are properly sealed. -
Page 34: Section 12: User Instructions
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 12: USER INSTRUCTIONS 12.1 User Instructions 12.3 Common User Controls The CTU heaters are fully automatic and operate 12.3.1 Thermostat Limit Thermodisc from the external controls fitted on site. The only user controls at the heater are the: Burner Lockout Reset Button: See Page 28, Section 12.3.2... -
Page 35: Simple Fault Finding
SECTION 12: U NSTRUCTIONS 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 reasons for the heater not operating are:... -
Page 36: Section 13: Servicing
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 13: SERVICING 13.1 Servicing Instructions 13.3 Fan/Motor Assembly Maintenance After commissioning, the heater will require The main fan bearings are permanently sealed and maintenance to be carried out annually. If the heater do not need lubrication. -
Page 37: Section 14: Conversion Between Gases
SECTION 14: C ONVERSION ETWEEN ASES SECTION 14: CONVERSION BETWEEN GASES 14.1 General Conversion between 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 other is the same for all types of heaters. -
Page 38: Section 15: Troubleshooting
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL SECTION 15: TROUBLESHOOTING 15.1 General Installation Code and Annual Inspections: All ROBERTS installations and service of GORDON ® equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts- Gordon and conform to all requirements set forth ROBERTS GORDON... -
Page 39: Troubleshooting For Automatic Ignition Burner Systems
SECTION 15: T ROUBLESHOOTING 15.2 Troubleshooting For Automatic Ignition Burner Systems There are two burner controls used: Honeywell S4563C and S4565C. They both have similar operating sequences. To measure flame current, connect a 0 - 50 μA DC meter in series with the flame probe. -
Page 40: Troubleshooting For Flame Supervision System
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 15.3 Troubleshooting for Flame Supervision System NOTE: Minimum flame probe current 1 μA DC. Typical flame probe current 3-5 μA DC. 15.4 Troubleshooting for Solenoid Valves... -
Page 41: Section 16: Removal And Replacement Parts
SECTION 16: R EMOVAL AND EPLACEMENT ARTS 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 turn the latch 90°. -
Page 42: Burner Compartment
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 16.2 Burner Compartment The burner compartment is a sealed compartment. Following any work, re-seal the compartment with the gas pipe rubber seal fully in place and all screws fitted and tight. 16.2.1 Burner Injectors Ensure gas tight fitting of injectors. -
Page 43: Ignition Electrode And Flame Probe
SECTION 16: R EMOVAL AND EPLACEMENT ARTS 16.3 Ignition Electrode and Flame Probe To replace the ignition electrode or flame probe, remove the electrical lead and screw. Pull out from mounting. Refit in reverse ensuring that the gap to burner is as shown in the front view of the burner compartment. -
Page 44: Flue Fan
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 16.4 Flue Fan Remove screws securing outlet flange to the flue adapter. Remove screws securing flue fan mounting plate to vent box. Remove screws securing mounting plate to fan. Refit in reverse. Use new gaskets. -
Page 45: Pressure Switch
SECTION 16: R EMOVAL AND EPLACEMENT ARTS 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. Carry out a commission after working on or changing a pressure switch. -
Page 46: Ignition Control
® COMBAT CTU U EATERS NSTALLATION PERATION AND ERVICE ANUAL 16.6 Ignition Control • Check that the fan blades are free to rotate before turning on the power to the fan. IT IS IMPORTANT THAT ONLY THE CORRECT IGNITION CONTROL SPECIFIED FOR EACH •... -
Page 47: Fan Data
SECTION 16: R EMOVAL AND EPLACEMENT ARTS • Use only genuine ROBERTS GORDON ® • Set all fans to operate at the same speed. replacement parts. The three speed winding connections are: Low speed: White N, Red Live The other two windings are "parked"... - Page 51 SECTION 16: R EMOVAL AND EPLACEMENT ARTS Roberts-Gordon Europe Limited Roberts-Gordon, LLC...