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Roberts Gorden Combat CTCU 11, Operation And Service Manual

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Roberts Gorden Combat CTCU 11 Operation And Service Manual Download Page 28

COMBAT

®

 CTCU U

NIT

 H

EATER

 I

NSTALLATION

 O

PERATION

 

AND

 S

ERVICE

 M

ANUAL

22 

SECTION 14: TROUBLESHOOTING

14.1 General

Replace axial fan.

If problems persist, contact

Roberts-Gordon Ltd. at

Tel: +44 (0)1902 498733

www.rg-inc.com

Heater Operating

TROUBLESHOOT ENDS.

No

Replace limit thermostat.

The limit thermostat has

tripped.

See Section 11.3.2.

No

Use 14.2 to test burner.

Has burner “Locked Out”?

Yes

No

With external controls on,

does the burner continue

through the heating cycle?

No

Yes

Does the fan run?

No

Use 14.5 to test fan.

Yes

Yes

Use 14.2 to test burner.

Is Red lockout

warning light on?

Yes

No

Turn on supplies.

Are gas & electrical

supplies on?

No

Yes

Start

Yes

WARNING

E

xplosion

 

Hazard

Installation

 

must

 

be

 

done

 

by

 

a

 

registered

 

installer/

contractor

 

qualified

 

in

 

the

 

installation

 

and

 

service

 

of

gas-fired

 

heating

 

equipment

 

or

 

your

 

gas

 

supplier.

Failure

 

to

 

follow

 

these

 

instructions

 

can

 

result

 

in

 

death,

injury

 

or

 

property

 

damage.

For your safety and optimum heater performance, use only ROBERTS GORDON

®

 replacement parts.

Conduct Commissioning procedure as shown 

on Page 15, Section 10

.

Summary of Contents for Combat CTCU 11

Page 1: ...r Failure to follow these instructions can result in death injury or property damage WARNING Installation must be done by a registered installer contractor qualified in the installation and service of gas fired heating equipment or your gas supplier Improper installation adjustment alteration service or maintenance can result in death injury or property damage Read the installation operation and s...

Page 2: ......

Page 3: ...aled Installation 11 7 2 Open Flued Installation 11 7 3 Building Ventilation 11 SECTION 8 Gas Piping 12 8 1 Connections 12 SECTION 9 Wiring and Electrical Information 13 9 1 Electrical Supply 13 9 2 Remote Controls 13 9 3 CTCUA Wiring Diagram Models 7 32 14 SECTION 10 Commissioning 15 10 1 Pre Commission Checks 15 10 2 Begin Commissioning 15 10 3 Complete the Commissioning 17 SECTION 11 User Instr...

Page 4: ......

Page 5: ...tional 8 Figure 5 Flue and Roof Detail 9 Figure 6 Vertical and Horizontal Flue Termination Type B22 Appliance 10 Figure 7 Vertical and Horizontal Flue Termination Type C12 C32 C62 Appliances 10 Figure 8 Gas Connection with Stainless Steel Flex Connector 12 Figure 9 Automatic Burner Control Box Sequence 16 Figure 10 Gas Valve for Heater Models 7 32 16 Figure 11 Heater Operating Sequence 18 ...

Page 6: ......

Page 7: ...ility Directive and the Machinery Directive for use on natural gas and LPG when installed commissioned and maintained in accordance with these instructions These instructions refer to appliances designed to operate in the European Union Appliances designed for other countries non European Union are available on request This appliance must be installed in accordance with the local and national code...

Page 8: ... hang or suspend anything from heater To ensure that there is sufficient ventilation in the area to comply with the requirements of all relevant local and national codes 2 1 Clearances to Combustibles In all situations clearances to combustibles must be maintained Caution must be used when running the heater near combustible materials such as wood paper rubber etc A wall tag is on the back cover o...

Page 9: ... and correct operation 3 4 Clearances to Combustibles Clearances must be as indicated on Page 4 Figure 1 If clearances to combustibles are not indicated then installation clearances apply 3 5 Ventilation It is important to ensure that there is adequate air circulation around the heater to supply air for combustion ventilation and distribution in accordance with local and national codes 3 6 Gas Sup...

Page 10: ... 15 cm Clearances to Combustibles Wall Terminal Roof Terminal Air Intake Flue 15 cm 2 5 3 5 m 3 m 25 cm Installation Clearances 3 m Roof Terminal If installed at low levels where individuals can come in contact with hot heat exchanger components adequate guarding must be provided All distances are minimum clearance requirements for service access air flow and safety The heater must always be insta...

Page 11: ...tre of Flue Top Option mm in 151 5 9 151 5 9 151 5 9 172 6 8 149 5 9 D Centre of Flue mm in 68 2 7 68 2 7 68 2 7 46 1 8 59 2 3 Weight kg 28 30 5 38 5 41 52 3 Rear View Top View Air Intake on Model 22 728 A Gas Supply B 171 Lockout Reset Electrical Connection Flue Air Intake 45 85 D 448 120 End View 660 514 Mounting Holes 422 Mounting Holes 448 265 14 C 171 120 Air Intake Optional Position Flue Opt...

Page 12: ... 15 CTCU 22 CTCU 27 CTCU 32 Heat Input Gross CV kW Btu h x 1000 8 5 29 13 4 46 18 3 62 27 5 94 33 113 38 5 131 Heat Input Net CV kW Btu h x 1000 7 7 26 12 1 41 16 5 56 24 8 85 29 7 101 34 7 118 Approximate Heat Output kW Btu h x 1000 7 1 24 11 1 38 15 1 52 23 78 27 2 93 31 7 108 Natural Gas G20 Data Inlet Pressure 20 mbar 7 8 in WG Min 17 mbar 6 8 in WG Max 25 mbar 10 in WG Burner Pressure mbar 9 ...

Page 13: ...unting holes Screw sizes less than M10 may not be used In order for the wall mounting brackets to adequately carry the weight of the heater it must be installed with best building practice Figure 2 Suspension Methods Existing cabinet screws must be re used WARNING Crush Hazard Use 10 mm steel drop rod minimum Failure of the supports can result in death injury or property damage Cone Point Set Pin ...

Page 14: ...Wall Mounting Bracket Arm Right 111WALL1R 1 Wall Mounting Bracket Vertical 111WAL2 2 Wall Mounting Bracket Diagonal 111WAL3 2 M8 x 85 mm Hex Head Bolt 97311405 6 M8 Lock Nut with Nylon Insert 92204504 6 M8 Flat Washer 95204502 6 M8 Lockwasher 96404502 6 Push in Louvre and compress spring to remove opposite end first Install Vertical Louvre Brackets top and bottom with supplied screws Install Verti...

Page 15: ...takes must be adequately supported so that the heater does not bear the weight of the pipes For flue termination See Page 9 Figure 5 through Page 10 Figure 7 6 3 Type C12 C32 C62 Appliance Room Sealed The heaters are designed to be installed as room sealed appliances The flue and air intake are run as separate pipes to the special concentric wall or roof terminal See Page 10 Figure 7 The wire mesh...

Page 16: ...l and Horizontal Flue Termination Type C12 C32 C62 Appliances Wall Terminal Flue Masterflash Masterflash Roof Terminal Vertical Option Horizontal Option Flue Wall Plate Wall Terminal Flue Roof Terminal Flue Air Intake Air Intake Manifold Manifold Vertical Option Plastic Cup Masterflash Horizontal Option Remove Internal Wire Mesh Remove Internal Wire Mesh ...

Page 17: ...nge rate is at least 0 5 h additional high and low level ventilation will not be required For a building having an air change rate less than 0 5 h ventilation will be necessary in accordance with local and national codes Ventilation direct to outside must be provided as follows Heaters up to 70 kW heat input 5 0 cm2 per kW of rated heat input 7 3 Building Ventilation Where ventilation is required ...

Page 18: ...ately 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 For suspended heaters use an approved metal flexible connection between the isolating valve and the heater To reduce pressure loss use one pipe size larger than the heater gas connection IMPORTANT The complete installati...

Page 19: ...See Page 14 Section 9 3 9 2 1 Burner Controls Thermostat Controls to operate the burner must be connected between L1 and T2 9 2 2 Positioning Room Thermostats or ROBERTS GORDON Control A room thermostat or ROBERTS GORDON control should be mounted on a wall or column at a height of approximately 1 5 metres from the floor to measure the ambient temperature It should be clear of both cold draughts an...

Page 20: ...E LOCKOUT SITE WIRING 230 V 50 Hz SUPPLY GROUND NEUTRAL THERMOSTAT REMOTE FAN ON REMOTE LOCKOUT INDICATION REMOTE LOCKOUT RESET LINE RESET WITH INDICATOR LIGHT EMC FILTER FAN DELAY THERMOSTAT THERMOSTAT L1 N T1 T2 S3 B4 L1 N T1 T2 S3 B4 BLACK SENSE IGNITION IGNITION CONTROL BLACK GAS VALVE 7 POLE PLUG 7 POLE SOCKET BROWN BROWN IGNITION CONTROL 4 5 1 2 NOTE If any of the original wire supplied with...

Page 21: ...installation including the gas meter must be inspected tested for soundness and purged in accordance with local and national codes Ensure that the air is fully purged from the heater inlet pipe up to the main gas valve inlet test nipple 10 1 4 Mechanical Checks 1 Check that the fan is free to run and delivery louvres are turned to give required air deflection 2 Check that the flue and air intake f...

Page 22: ...rol Required Incoming Signals Flue Fan Pressure Switch P C NO NC 30 Sec Purge Purge time begins at pressure switch change over If at any stage the flame fails the control will go into lockout The red light inside the RESET switch will illuminate and the control will need to be manually reset before any further start attempt can be made Regulator Under Cover Inlet Pressure Gas Inlet Ignition Contro...

Page 23: ...ting must be carried out with all covers in place The flue gas is sampled in the flue within 1 meter of the heater The values of CO2 should be between 5 7 to 8 0 for natural gas and 6 8 to 9 2 for LPG dependant upon model The CO will be up to 80 ppm 0 008 dry air free dependant upon model Temperature rise of the flue gases above ambient should be approximately 130 C to 160 C Seal test hole in flue...

Page 24: ...ater will illuminate when the control has gone to lockout This may be caused by flame failure Press the reset button on the back of the heater See Page 5 Section 4 1 or the remote reset if installed on site 11 4 Lighting Instructions 11 4 1 To Turn On Heater 1 Ensure that the electrical and gas supplies to the heater are on Check that the on site con trols are ON NOTE The thermostat setting must b...

Page 25: ...on it will go to lockout This will be indicated by the red light on the back of the heater or at the remote indicator if fitted 1 Press in and release the lockout reset button If a remote reset is not fitted a reset button is on the back of the heater See Page 5 Section 4 1 Lockout should not occur during normal operation of the heater and indicates there is a fault condition which must be correct...

Page 26: ...en the door and remove the burner compart ment cover See Page 27 Section 15 2 2 Clean any deposits from the main burner which may have formed in the injectors or venturi of the burner See Page 27 Section 15 2 3 Remove the ignition electrode and flame probe Check condition of ignition electrode and flame probe Clean off any deposits which may have been formed check condition of ceramic insulators R...

Page 27: ... manifold and pull out the manifold 3 Remove inshot burners by rotating them and sliding out the bracket 4 Remove the main burner injectors 5 Replace with the injectors for the new gas ensuring a gas tight seal 6 Refit all components in reverse order 13 3 Gas Valves All gas valves used on the CTCU have pressure regulators that may be set to operate on natural gas or LPG Conversion is carried out b...

Page 28: ...inue through the heating cycle No Yes Does the fan run No Use 14 5 to test fan Yes Yes Use 14 2 to test burner Is Red lockout warning light on Yes No Turn on supplies Are gas electrical supplies on No Yes Start Yes WARNING Explosion Hazard Installation must be done by a registered installer contractor qualified in the installation and service of gas fired heating equipment or your gas supplier Fai...

Page 29: ...r plug in connections faulty Repair or replace as necessary Check for too much flue air inlet duct Check for blockage in combustion air circuit Check for faulty air pressure switch See Section 15 5 Does air pressure switch change over No Yes Turn on controls Is 230 V supply at fan connections Does flue fan run No Are external controls on No Yes Yes Is red lockout light on No Yes Press in lockout r...

Page 30: ...rity correct Is flame probe circuit correct Is there a current flowing in the flame probe circuit with no flame present Yes No Does lockout occur when there is a flame present Yes Is the connecting lead damaged Is the flame probe damaged or touching earthed components No Is the flame present and at least 1 µA DC flame current Connect a DC ammeter in series with the flame probe Yes No Yes Yes No ST...

Page 31: ...n valve turns on No Yes Is gas pressure at inlet of the valve correct for gas type Note pressure found No Yes START If problems persist contact Roberts Gordon Ltd at Tel 44 0 1902 498733 www rg inc com Fan Operating TROUBLESHOOT ENDS No Fan motor faulty Replace with correct type Is there 230 V between terminals L1 and N Replace fan delay thermostat Replace fan delay thermostat Is power supply 230 ...

Page 32: ... Gas Valve Remove the gas supply pipe at the heater inlet Replace in reverse order Verify that the gas flow direction of the valve is correct Use a minimum amount of gas seal on the thread joint Check that all the joints are leak free Reset gas valve See Page 17 Section 10 2 2 IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVE IS USED WHEN REPLACING THESE CONTROLS Disconnect wire harness Unplug contr...

Page 33: ...73 0 081 0 081 0 081 Marking 50 49 49 46 46 46 RG P N 91930050 91930049 91930049 91930046 91930046 91930046 Natural Gas G25 Injector size mm Ø 1 99 2 06 2 06 2 26 2 261 2 261 in Ø 0 0785 0 081 0 081 0 089 0 089 0 089 Marking 47 46 46 43 43 43 RG P N 91930047 91930046 91930046 91930043 91930043 91930043 LPG Propane G31 and LPG Butane G30 Injector size mm Ø 1 18 1 18 1 18 1 25 1 25 1 25 in Ø 0 0465 ...

Page 34: ...ode Flame Probe Fan Thermostat Flame Probe Burners Description Part Number Spark Electrode 90427411 Automatic Ignition Flame Probe 90439300 Burners 92000002 Fan Thermostat 90412102 Limit Thermostat 90412100 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 th...

Page 35: ...exible Duct Vent Box Gaskets Mounting Plate to Vent Box fixing screws Mounting Plate to Flue Fan fixing screws Air Intake Adapter Intake Exhaust Covers To remove the fan remove 3 screws securing the fan and mounting plate to the vent box To remove the fan from the mounting plate remove the 4 screws Refit in reverse order To change the flue and air intake orientation from back to top remove the fan...

Page 36: ...r changing a pressure switch See Page 15 Section 10 Carbon Monoxide Hazard Use correct pressure switch specified for each model Use of incorrect pressure switch could cause unsafe condition Failure to follow these instructions can result in death or serious injury WARNING Pressure Switch CTCU 7 CTCU 11 CTCU 15 CTCU 22 CTCU 27 CTCU 32 RG P N 90439812 90439812 90439812 90439803 90439803 90439803 Col...

Page 37: ...n above Fit rubber washers to the guard mountings to reduce vibration Check that the fan blades are free to rotate before turning on the power to the fan Strictly comply with the colour code of the fan wires to ensure correct operation See Page 14 Section 9 3 wiring diagram Use only genuine ROBERTS GORDON replacement parts 15 8 Fan and Limit Thermostats 15 8 1 Removal and Replacement 1 Pull off th...

Page 38: ......

Page 39: ......

Page 40: ...2 Open the manual gas valve in the heater supply line 3 Turn on electric power to the heater 4 Set the thermostat to desired setting above ambient temperature The automatic starting sequence begins NOTE Following long shutdown periods the burner control may go to to LOCKOUT during the start sequence Push the reset button to recommence firing Contact service department if LOCKOUT continues see manu...

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